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A - ENGINE/VIN ID
Article Text
1984 Mazda RX7
For iluvmyrx7.com
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, June 08, 2002 10:41PM
ARTICLE BEGINNING
1983-88 ENGINE PERFORMANCE
Mazda VIN Code Identification
RX7
MODEL IDENTIFICATION
Fig. 1:
VIN Code Identification
VIN CODE ID EXPLANATION
Numbers preceding the explanations in the legend below refer
to the sequence of characters as listed on VIN identification label in
Fig. 1. The legend listed below will also be found in Fig. 1.
1 Manufacturing Country
J * Japan
2 Make
M *
Mazda Motors Corp., Japan
3 Type
1 *
V *
Passenger Car
Passenger Car
4-5 Model
FB * RX7 1983-85
FB * RX7 1986-88
6-7 Body Style
33 * HB RX7
35 * Convertible
8 Modification Code
1 * Not Specified By Manufacturer
9 VIN Check Digit
1
*
Constant For All Models
10 Vehicle Model Year
D * 1983
E * 1984
F * 1985
G * 1986
H * 1987
J * 1988
11 Assembly Plant
0 * Hiroshima, Japan
12-17 Serial Number
* Sequential Production Number
END OF ARTICLE
A - ENGINE/VIN ID
Article Text (p. 2)1984 Mazda RX7For iluvmyrx7.com
Copyright © 1998
AIR INJECTION SYSTEM - CARBURETED
Article Text
1984 Mazda RX7
For iluvmyrx7.com
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, June 08, 2002 10:42PM
ARTICLE BEGINNING
1984 Exhaust Emission Systems
CARBURETED MODELS
AIR INJECTION SYSTEM
DESCRIPTION
This system controls CO, HC and NOx emissions by injecting
secondary air into the exhaust system to cause further burning of
exhaust gases. System consists of an air pump, 2 check valves, an air
control valve, relief solenoid valve, switching solenoid valve, heat
hazard sensor and catalytic converters.
Air is drawn from the clean side of the air cleaner by the
air pump and directed to the air control valve under pressure. From
the air control valve, secondary air is directed (by the switching
solenoid valve) "downstream" to the pellet converter or "upstream" to
the exhaust port.
The secondary air system contains 2 check valves to prevent
exhaust gas from leaking back into the air pump. The switching
solenoid valve directs secondary air through the air control valve
"downstream" and/or "upstream", based upon engine temperature,
manifold vacuum and engine speed.
The relief solenoid valve controls the amount of air injected
according to intake manifold vacuum. Under normal operating
conditions, part of the secondary air supplied by the air pump is
directed back to the air cleaner. The heat hazard sensor lights an
exhaust temperature warning light on the instrument panel if exhaust
temperatures become excessive.
Fig. 1:
Mazda RX7 Air Injection System
TESTING
AIR PUMP
1) With engine at normal operating temperature, inspect all
hose connections for leaks. Check for pump noise and belt tension.
2) Stop engine and disconnect air line at air control valve.
Connect hose to a pressure gauge. Connect tachometer to engine.
3) Start engine and run at idle speed. Gauge should register
more than 1.64 psi (.12 kg/cmý) with engine at 800 RPM. If pump
pressure is below specification, replace air pump.
CHECK VALVES
Intake Manifold Valve
Disconnect the air hose at the air control valve. Connect a
tachometer to the engine. Start the engine. Disconnect the connector
from air switching solenoid valve. Increase engine speed to 1500 RPM.
Watch for exhaust leak. If leak exists, replace check valve.
Conveter Air Line Valve
Disconnect the air hose at the rear side of the intake
manifold. Connect a tachometer to the engine. Start the engine.
Increase engine speed to 1500 RPM. Watch for exhaust leak at air pipe
opening. If leak exists, replace check valve.
AIR CONTROL VALVE
1) After ensuring air pump and all hoses are correct, check
carburetor and air control valve attaching nuts for tightness. Warm
engine to normal operating temperature. Stop engine and connect a
tachometer.
2) Disconnect air cleaner-to-air control valve hose at air
cleaner. Place a finger over the hose opening. Increase the engine
speed and make sure that air flows out when the engine speed is 15002500 RPM or higher.
3) Run the engine at idling speed. Disconnect the vacuum
sensing tube (from relief solenoid valve to pipe) at the pipe. Air
should flow out from the air hose. Reconnect the vacuum sensing tube
and the air hose.
4) Disconnect the split air hose (from check valve to intake
manifold) at the intake manifold. Place a finger over the port
opening. Disconnect the vacuum sensing tube (from switching solenoid
to pipe) at the pipe.
5) Air should flow out from the port. Reconnect the vacuum
sensing tube and split air hose. If air control valve does not respond
as described, replace air control valve.
RELIEF SOLENOID VALVE
1) Disconnect vacuum sensing tubes from relief solenoid valve
and vacuum pipe. Blow through solenoid valve from vacuum sensing tube
"B" in Fig. 2. Air should pass through valve and escape from port "C".
2) Disconnect electrical connector from relief solenoid valve
and connect battery power to solenoid terminals. Blow through valve
from the vacuum sensing tube "B". Air should pass through valve and
escape through port "A" of the valve. If valve does not respond as
described, replace valve.
AIR INJECTION SYSTEM - CARBURETED
Article Text (p. 2)1984 Mazda RX7For iluvmyrx7.com
Copyright ©
Fig. 2:
Testing Relief Solenoid Valve
RELIEF SOLENOID VALVE SIGNAL CHECK
1) Warm engine to normal operating temperature. Connect
tachometer to engine. Disconnect connector from throttle sensor and
connect a jumper wire between terminals "A" and "C" of connector. See
Fig. 3.
2) Disconnect the vacuum sensing tube (from relief
solenoid valve to pipe) at the pipe. Place a finger over the vacuum
sensing tube opening. Start engine. Air should be sucked into the
tube.
3) Increase engine speed. Air should not be sucked into the
tube when engine speed is 3600-4400 RPM or higher. Disconnect the
connector from the catalyst thermosensor. Gradually increase the
engine speed and make sure that air is not sucked into the tube when
the engine speed is 1000-2000 RPM or higher.
4) Reconnect the connector to the catalyst thermosensor.
Disconnect the jumper wire and connect the connector to the throttle
sensor. Disconnect the sensor from the heat hazard sensor and connect
a jumper wire to both terminals of the connector. Make sure that air
is not sucked into the tube at any engine speed.
5) Disconnect the jumper wire and connect the connector to
the heat hazard sensor. Stop the engine and disconnect the connector
from the number 2 water temperature switch on the radiator. Disconnect
the connector from the number 1 water temperature switch.
6) Connect a jumper wire to both terminals of the connector.
Pull the choke knob out about .6" (15 mm). Start the engine. Gradually
increase the engine speed and make sure that air is not sucked into
the tube when the engine speed is 1000-2000 RPM or more.
7) Connect the vacuum sensing tube to the pipe. Stop the
engine and connect the jumper wire. Connect connector to the number 1
water temperature switch.
AIR INJECTION SYSTEM - CARBURETED
Article Text (p. 3)1984 Mazda RX7For iluvmyrx7.com
Fig. 3:
Testing Relief Solenoid Valve Signal
SWITCHING SOLENOID VALVE
1) Disconnect vacuum sensing tubes from switching solenoid
Copyright ©
valve and vacuum pipe. Blow through switching valve from vacuum
sensing tube "B". See Fig. 2. Air should pass through valve and
escape from port "C".
2) Disconnect electrical connector from switching solenoid
valve and connect battery power to terminals on valve. Blow through
hose again. Air should pass through valve and escape through port "A"
of the valve. If valve does not respond as described, replace
switching solenoid valve.
SWITCHING SOLENOID VALVE SIGNAL CHECK
1) Warm engine to normal operating temperature. Connect
tachometer to engine. Disconnect the connector from the throttle
sensor and connect a jumper wire to terminals "A" and "C" of the
connector. Disconnect the vacuum sensing tube (from switching solenoid
valve to pipe) at the pipe. See Fig. 3.
2) Place a finger over the vacuum sensing tube opening and
make sure air is sucked into the tube. Gradually increase the engine
speed and make sure that air is not sucked into the tube when engine
RPM is 1000-2000 RPM or more.
3) Disconnect the connector from the number 1 water
temperature switch and connect a jumper wire to both terminals of the
connector. Pull the choke knob out about .6" (15 mm). Increase the
engine speed and make sure that air is sucked into the tube at any
engine speed.
4) Disconnect the jumper wire from water temperature switch
connector and reconnect the connector to water temperature switch.
Disconnect the jumper wire from terminals "A" and "C" and connect the
connector to the throttle sensor.
5) Gradually increase the engine speed and make sure air is
sucked into tube at any engine speed. Air should not be sucked into
the tube if the engine is accelerated quickly. Reconnect the vacuum
sensing tube to pipe.
WATER TEMPERATURE SWITCHES
1) Remove number 1 switch from water pump. Remove number 2
switch from radiator lower tank. Place switch in water with a
thermometer and heat water gradually. On the number 1 switch, check
the temperature at which continuity does not exist between both
terminals in the connector.
2) On the number 1 switch, check the temperature at which
continuity exits between both terminals in the connector. For the
number 1 switch, there should be no continuity at temperatures above
146-169øF (63.5-76.5øC). For the number 2 switch, continuity should
exist temperatures above 52-66øF (12-18øC).
CHOKE SWITCH & MAGNET
Disconnect the connector from the choke switch. Check the
continuity between the numbered terminals in the connector using an
ohmmeter. With choke knob pulled out .3-.5" (8-12 mm), there should be
continuity between terminals 3 and 7 if switch is okay. With knob in
any position, there should be continuity between terminals 6 and 8 if
choke magnet is okay.
AIR INJECTION SYSTEM
diaphragm shaft. Before installing air horn, make necessary float
adjustments.
ADJUSTMENT SPECIFICATIONS
CARBURETOR ADJUSTMENT SPECIFICATIONS
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Application
Specification
RX7
Float Level In. (mm) ......................... .61-.65 (15.5-16.5)
Float Drop In. (mm) ........................ 1.98-2.02 (50.5-51.5)
Choke Linkage In. (mm) ....................... .040-.047 (1.0-1.2)
Accel. Cable Free Play In. (mm) ................ .04-.12 (1.0-3.0)
Choke Valve Opening In. (mm) ................... .22-.24 (5.6-6.2)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
END OF ARTICLE
CARBURETOR - NIKKI 4-B
Fig. 4:
Testing Choke Switch and Choke Magnet
CHOKE RELAY
Disconnect the connector from the relay. Check the continuity
between the numbered terminals using an ohmmeter. With battery voltage
applied between terminals 6 (positive) and 5 (negative), there should
be continuity between 3 and 4 and no continuity between 1 and 2. With
no power applied, there should be continuity between 1 and 2 and no
continuity between 3 and 4.
Fig. 5:
Checking Choke Relay
HEAT HAZARD SENSOR
1) Turn ignition on; "Overheat Exh. System" warning light
should glow. Start engine and warning light should go out. Remove
passenger seat, fold back carpeting and disconnect heat hazard sensor
connector.
2) Warning light should glow when jumper wire is connected to
both terminals of the connector. If warning light does not respond as
outlined, remove and test sensor. Wrap sensor and a thermometer in
aluminum foil (electrical connector must be exposed for access).
3) Place sensor and thermometer (wrapped in aluminum foil) in
container filled with oil. Place a second thermometer in container of
oil. See Fig. 6.
4) Connect a battery and test lamp to sensor connector. Test
lamp should glow. Gradually heat oil. Test lamp should go OFF when
temperature inside aluminum foil is 248-284øF (120-140øC). If sensor
AIR
- CARBURETED
Article
Text (p.
5)1984 Mazda RX7For iluvmyrx7.com
does INJECTION
not respondSYSTEM
as outlined,
replace heat
hazard
sensor.
NOTE:
Do not heat oil above 302øF (150øC).
Copyright ©
Fig. 6:
Testing Heat Hazard Sensor
PORT AIR SOLENOID VALVE
1) Warm up engine and run at idle speed. Connect a tachometer
to engine. Disconnect the connector from the throttle sensor and
connect a jumper wire to "A" and "C" terminals of the connector. See
Fig. 3. Connect a voltmeter to the port air solenoid terminal and
ground.
2) Increase engine speed and watch voltmeter. With engine
speed below 3000 RPM, voltage should be below 2 volts. With engine
speed between 3000-4000 RPM, voltage should be about 12 volts. At
above 4000 RPM, voltage should be below 2 volts.
3) Disconnect the jumper wire from "A" and "C". Position the
vehicle securely on a rolling load tester. Increase the vehicle speed
to to 50 MPH. At speeds below 50 MPH, reading should be below 2 volts.
At speed above 50 MPH, voltage should be approximately 2 volts.
CATALYST THERMO SENSOR
Disconnect the connector for the catalyst thermo sensor and
check for continuity. Sensor is no good if there is no continuity.
END OF ARTICLE
AIR INJECTION SYSTEM - CARBURETED
Article Text (p. 6)1984 Mazda RX7For iluvmyrx7.com
Copyright ©
AIR INJECTION SYSTEM - EFI
Article Text
1984 Mazda RX7
For iluvmyrx7.com
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, June 08, 2002 10:42PM
ARTICLE BEGINNING
1984 EXHAUST EMISSION SYSTEM
Mazda Air Management Systems - Fuel Injected Models
RX7
DESCRIPTION
The air management system consists of the following subsystems: Air Injection, Secondary Air Control, Air Induction and ByPass Air Control. The air injection system controls CO, HC and NOx
emissions by injecting secondary air into the exhaust system to cause
further burning of exhaust gases. System consists of an air pump, 2
check valves, an air control valve, relief solenoid valve, switching
solenoid valve, heat hazard sensor and catalytic converters.
Air is drawn from the clean side of the air cleaner by the
air pump and directed to the air control valve under pressure. From
the air control valve, secondary air is directed (by the switching
solenoid valve) "downstream" to the pellet converter or "upstream" to
the exhaust port.
The air induction system brings air into the engine for
combustion functions. The system consists of : Air Cleaner, Air Flow
Meter, Air Funnel, Throttle Chamber, Dynamic Chamber and Intake
Manifold.
The secondary air control system contains 2 check valves to
prevent exhaust gas from leaking back into the air pump. The switching
solenoid valve directs secondary air through the air control valve
"downstream" and/or "upstream", based upon engine temperature,
manifold vacuum and engine speed.
The By-Pass Air Control System (BAC) controls the amount of
by-pass air to maintain idling speed. System is controlled by a vent
solenoid valve and vacuum solenoid valve.
COMPONENT OPERATION
CONTROL VALVES
Air Control Valve
Directs air to 1 of 3 locations; exhaust port, 3-way catalyst
or back to the relief silencer. Consists of air relief valve, air
switching valve and anti-afterburn valve.
Air Supply Valve
Supplies by-pass air into dynamic chamber during A/C and
power steering operation.
By-Pass Air Control Valve
Controls amount of by-pass air to maintain idling speed.
Controlled by vent solenoid valve and vacuum solenoid valve.
Check & Cut Valve
Releases excessive pressure or vacuum in fuel tank to
atmosphere. Prevents fuel loss if vehicle overturns.
Relief Solenoid Valve
Relieves secondary air to air cleaner when unnecessary.
Split Air Solenoid Valve
Controls amount of split air. The valve increases split air
when the overdrive switch is open.
Switching Solenoid Valve
Switches secondary air to exhaust port or rear catalyst.
Vacuum Control Solenoid Valve
Cuts out vacuum to distributor during deceleration.
SENSORS
Heat Hazard Sensor
Detects floor temperature and sends signal to relief solenoid
valve control unit.
Intake Air Temperature Sensor
Detects intake air temperature and controls pressure control
valve and BAC valve through control unit.
Water Thermo Sensor
Detects engine coolant temperature and sends signal to
control unit.
SWITCHES
Clutch and Neutral Switches
Detects in-gear condition and sends signal to control unit.
Clutch switch closes when clutch pedal is depressed and opens when
pedal is released. Neutral switch closes when transmission is in
neutral and opens when transmission is in gear.
Overdrive Switch
Controls ACV solenoid, when transmission is in 5th gear the
over drive switch is open. All other gears the overdrive switch is
closed.
Vacuum Switch
Detects intake manifold vacuum and sends signal to control
unit. The vacuum switch opens when theres approx. 15 in. Hg of vacuum.
Fig. 1:
Air Injection System (RX7 Fuel Injected Models)
TESTING
AIR INJECTION & SECONDARY AIR CONTROL
AIR INJECTION SYSTEM
Air Pump
1) With engine at normal operating temperature, inspect all
hose connections for leaks. Check for pump noise and belt tension.
2) Stop engine and disconnect air line at air control valve.
Connect hose to a pressure gauge. Connect tachometer to engine. See
Fig. 2.
3) Start engine and run at idle speed. Gauge should register
more than 1.64 psi (.12 kg/cmý) with engine at 800 RPM. If pump
pressure is below specification, replace air pump.
Fig. 2:
Connecting Pressure Gauge to Air Pump
Intake Manifold Check Valve
Disconnect the air hose at the air control valve. Connect a
tachometer to the engine. Start the engine. Disconnect the connector
from air switching solenoid valve. Increase engine speed to 1500 RPM.
Watch for exhaust leak. If leak exists, replace check valve.
Converter Air Line Check Valve
Disconnect the air hose at the rear side of the intake
manifold. Connect a tachometer to the engine. Start the engine.
Increase engine speed to 1500 RPM. Watch for exhaust leak at air pipe
opening. If leak exists, replace check valve.
Air Control Valve
1) After ensuring air pump and all hoses are correct, check
carburetor and air control valve attaching nuts for tightness. Warm
engine to normal operating temperature. Stop engine and connect a
tachometer.
2) Disconnect air cleaner-to-air control valve hose at air
cleaner. Place a finger over the hose opening. Increase the engine
speed and make sure that air flows out when the engine speed is 15002500 RPM or higher. See Fig. 3.
Fig. 3:
Checking Air Control Valve
3) Run the engine at idling speed. Disconnect the vacuum
sensing
tube (from
relief- EFI
solenoid
valve(p.to3)
pipe)
at the
pipe.
Air
1984
Mazda
RX7For
iluvmyrx7.com
AIR INJECTION
SYSTEM
Article Text
Copyright © 1998 Mitchell R
should flow out from the air hose. Reconnect the vacuum sensing tube
and the air hose.
4) Disconnect the split air hose (from check valve to intake
manifold) at the intake manifold. Place a finger over the port
opening. Disconnect the vacuum sensing tube (from switching solenoid
to pipe) at the pipe.
5) Air should flow out from the port. Reconnect the vacuum
sensing tube and split air hose. If air control valve does not respond
as described, replace air control valve.
Relief Solenoid Valve
1) Disconnect vacuum sensing tubes from relief solenoid valve
and vacuum pipe. Blow through solenoid valve from vacuum sensing tube
"B", air should pass through valve and escape from port "C".
2) Disconnect electrical connector from relief solenoid valve
and connect battery power to solenoid terminals. Blow through valve
from the vacuum sensing tube "B". Air should pass through valve and
escape through port "A" of the valve. If valve does not respond as
described, replace valve. See Fig. 4.
Fig. 4:
Testing Relief Solenoid Valve
Switching Solenoid Valve
1) Disconnect vacuum sensing tubes from switching solenoid
valve and vacuum pipe. Blow through switching valve from vacuum
sensing tube "B". Air should pass through valve and escape from port
"C".
2) Disconnect electrical connector from switching solenoid
valve and connect battery power to terminals on valve. Blow through
hose "B" again. Air should pass through valve and escape through port
"A" of the valve. If valve does not respond as described, replace
switching solenoid valve.
Switching Solenoid Valve Signal Check
1) Warm engine to normal operating temperature. Connect
tachometer to engine. Disconnect the connector from the throttle
sensor and connect a jumper wire to terminals of the connector.
Disconnect the vacuum sensing tube (from switching solenoid valve to
pipe) at the pipe.
AIR
2) Place a finger over the vacuum sensing tube opening and
INJECTION SYSTEM -
make sure air is sucked into the tube. Gradually increase the engine
speed and make sure that air is not sucked into the tube when engine
RPM is 1000-2000 RPM or more.
3) Disconnect the connector from the number 1 water
temperature switch and connect a jumper wire to both terminals of the
connector. Pull the choke knob out about .6" (15 mm). Increase the
engine speed and make sure that air is sucked into the tube at any
engine speed.
4) Disconnect the jumper wire from water temperature switch
connector and reconnect the connector to water temperature switch.
Disconnect the jumper wire from terminals and connect the connector to
the throttle sensor.
5) Gradually increase the engine speed and make sure air is
sucked into tube at any engine speed. Air should not be sucked into
the tube if the engine is accelerated quickly. Reconnect the vacuum
sensing tube to pipe.
Water Temperature Switches
1) Remove number 1 switch from water pump. Remove number 2
switch from radiator lower tank. Place switch in water with a
thermometer and heat water gradually. On the number 1 switch, check
the temperature at which continuity does not exist between both
terminals in the connector.
2) On the number 1 switch, check the temperature at which
continuity exits between both terminals in the connector. For the
number 1 switch, there should be no continuity at temperatures above
146-169øF (63.5-76.5øC). For the number 2 switch, continuity should
exist temperatures above 52-66øF (12-18øC).
BY-PASS AIR CONTROL SYSTEM
Fig. 5:
By-Pass Air Control System Diagram
BY-PASS AIR CONTROL SYSTEM
By-Pass Air Control System Check
1) Warm up engine and run at idling speed. Turn headlight
switch on an disconnect vent and vacuum solenoid valve connector.
2) Connect vent and vacuum solenoid valve connector and make
sure that engine speed increases to 800 RPM. If RPM does not increase,
perform component test.
Vent Solenoid Valve
AIR INJECTION SYSTEM
1) Disconnect intake tube from vent solenoid and remove
connector. Blow through vent solenoid valve from intake tube and make
sure that air does not pass.
2) Apply power to vent solenoid terminals. See Fig. 6. Blow
through vent solenoid valve from intake tube and make sure that air
passes. If vent solenoid does not pass air, replace unit.
Fig. 6:
Vent Solenoid Valve
Vacuum Solenoid Valve
1) Disconnect vacuum hose from solenoid valve. Remove vacuum
solenoid valve connector. Blow through vacuum solenoid valve from
connecting tube side and make sure that air passes through solenoid
valve. See Fig. 7.
2) Apply electrical power to vacuum solenoid connector. Blow
through vent solenoid valve from vacuum supply side and make sure that
air does not pass. If air passes through valve, replace unit.
Fig. 7:
Air Supply Valve
Air Supply Valve
1) Start engine and run at idling speed. Turn A/C switch on
and make sure that engine speed does not decrease.
2) Disconnect air supply valve connector and make sure that
engine speed decreases. Reconnect air supply valve connector and make
sure that engine speed increases to idling speed (800 RPM). If air
supply valve does not function, replace unit. See Fig. 8.
AIR INJECTION SYSTEM - EFI
Article Text (p. 6)1984 Mazda RX7For iluvm
Fig. 8:
Testing Air Supply Valve
Adjusting Air Supply Valve
1) Warm up engine and run at idling speed. Connect a
tachometer to engine. Disconnect vent and vacuum solenoid valve
connector.
2) Disconnect vent and vacuum solenoid valve connector. Check
idling speed and adjust, if necessary. Disconnect air supply valve
connector and apply electrical power to air supply.
3) Make sure engine speed is within 1000-1700 RPM. If engine
speed is not within the RPM range, remove blind cap and adjust engine
speed by turning adjusting. After adjusting, install blind cap.
Power Steering Switch
1) Start engine and run at idling speed. Disconnect power
steering switch connector.
2) Connect a volt/ohmmeter to the power steering switch. Turn
steering wheel either right or left, and make sure there is continuity
between switch terminals.
3) When oil pressure is above 427 psi (30.0 kg/cmý), power
steering switch should be closed. When oil is below 427 psi (30.0
kg/cmý), power steering switch should be open.
Clutch Switch
Disconnect clutch switch connector. Connect volt/ohmmeter to
clutch switch, and then check continuity between switch terminals.
When clutch pedal is depressed, switch should be closed. When clutch
pedal is released, switch should be open. See Fig. 9.
AIR INJECTION SYSTEM - EFI
Article Text (p. 7)1984 Mazda RX7For iluvmyrx7.com
Fig. 9:
Testing Clutch Switch
Neutral Switch
Disconnect neutral switch connector. Connect volt/ohmmeter to
neutral switch, and then check continuity between switch. When
Copyright © 1998 Mitchell R
transmission is in neutral, switch should be closed. When transmission
is in gear, switch should be open. See Fig. 10.
Fig. 10:
Testing Neutral Switch
AIR INDUCTION SYSTEM
Throttle Chamber
1) The No. 1 secondary throttle valve starts to open when the
primary valve opens 15ø and completely opens at the same time when the
primary valve fully opens.
2) Check the clearance between the primary throttle valve and
the wall of the throttle bore when the No. 1 secondary valve starts to
open.
3) If the clearance is not within .043-.067" (1.1-1.7 mm),
bend the tab until the proper clearance is obtained. See Fig. 11.
Fig. 11:
Checking Throttle Valve Clearance
Fast Idle Operation
1) For this check the engine and throttle chamber must be at
77øF (25øC). For proper fast idle operation the matching mark on fast
idle cam must be aligned with center of cam roller.
2) If the matching mark and center of the cam roller do not
align, turn the cam adjusting screw until proper alignment is
obtained. See Fig. 12.
NOTE:
Fast idle adjustment in unnecessary unless it has been
tampered with.
AIR INJECTION SYSTEM - EFI
A
Fig. 12:
Checking Fast Idle Cam
3) When the connect matching mark aligns with the center of
the cam roller, clearance (throttle chamber to primary throttle valve)
should be .016-.02" (.4-.5 mm). If clearance is off, turn the fast
idling adjusting screw to bring into specifications.
Accelerator Linkage
Remove the air funnel and, with the accelerator pedal fully
depressed, observe the position of the throttle valves. They should be
horizontal (wide open position). Check that the accelerator linkage
returns fully and does not bind. See Fig. 13.
Fig. 13:
Checking Accelerator Linkage
Double Throttle Diaphragm
1) Disconnect vacuum sensing tube from double throttle
diaphragm. Apply vacuum of more than 7.8 in. Hg to the double throttle
diaphragm.
2) Make sure that the No.2 secondary throttle valve is fully
closed to its movable range. Check the calibration of the double
throttle diaphragm. It should start to open 4.7 in Hg and be fully
opened 0-1.8 in Hg. See Fig. 14.
AIR INJECTION SYSTEM - EFI
Article Text (p. 9)1984 Mazda RX7For iluvmyrx7.com
Copyright © 1998 Mitchell R
Fig. 14:
Checking Double Throttle Diaphragm
Delay Valve
1) Disconnect vacuum delay valve. Connect approx. 3.5 Ft. of
vacuum tube to the vacuum pump tester. Completely shut the other side
of the vacuum delay valve with your thumb.
2) Apply a vacuum of over 19.7 in. Hg by using the vacuum
pump tester. Release your thumb from vacuum delay valve and check time
required for vacuum reading to decrease to 3.9 in. Hg from 15.7 in. Hg
in approx. 13 seconds.
Water Thermo Valve
1) Remove water thermo valve from engine. Immerse water
thermo valve in a container of water.
2) Heat up water gradually and observe the temperature. Below
approx. 140øF (60øC) air should pass from top vacuum line to bottom
vacuum line. Above approx. 140øF (60øC) air should pass from bottom
vacuum line too orifice on top of thermo valve.
Actuator & Auxiliary Port Valve
Remove air hose and connect a pressure gauge to the valve.
Apply low compressed air to the actuator and check operation. To start
movement approx. 1.8 psi. To finish movement approx. 2.7 psi.
END OF ARTICLE
1984 Mazda RX7For iluvmyrx7.com
AIR INJECTION SYSTEM - EFI
Article Text (p. 10)
Copyright © 1998 Mitchell
CARBURETOR - NIKKI 4-BBL
Article Text
1984 Mazda RX7
For iluvmyrx7.com
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, June 08, 2002 10:43PM
ARTICLE BEGINNING
1984 Nikki Carburetors
NIKKI 4-BARREL
Mazda RX7
DESCRIPTION
Carburetor is of 4-barrel, 2-stage design. Primary stage
includes idle system, slow speed circuit, accelerator pump system and
main metering system. In addition, Federal models are equipped with a
sub-zero starting device which admits fluid into the primary stage.
Secondary stage contains secondary vacuum diaphragm
operating system, stepping circuit and main metering system. Choking
is accomplished through a semi-automatic choke. Other features
include a deceleration control system, automatic choke return, hot
start assist, idle compensation and dashpot (manual transmission).
ADJUSTMENTS
NOTE:
For all on-vehicle adjustments not covered in this article,
see the appropriate TUNE-UP article.
FLOAT LEVEL
1) Before assembling air horn to main body, adjust float
level. Invert air horn and allow float to hang by its own weight.
2) Measure clearance between float and air horn gasket. See
Fig. 1. Clearance should be .61-.65" (15.5-16.5 mm). If not within
specifications, bend float seat to adjust.
Fig. 1:
Float Level Adjustment
FLOAT DROP
Turn air horn upright and allow float to hang by its own
weight. Measure distance between bottom of float and air horn gasket.
See Fig. 2. Distance should be 1.98-2.02" (50.5-51.5 mm). If not,
bend float stop to adjust.
Fig. 2:
Float Drop Adjustment
CHOKE LINKAGE
(FAST IDLE OPENING ANGLE)
Close choke valve fully and measure clearance between
primary throttle valve and wall of throttle bore. Set clearance to
.040-.047" (1.0-1.2 mm) by bending fast idle rod. See Fig. 3.
Fig. 3: Choke Linkage (Fast Idle Opening Angle)
Bend fast idle rod to adjust.
CHOKE VALVE OPENING ANGLE
NOTE:
Choke diaphragm No. 1 is the dual diaphragm assembly, choke
diaphragm No. 2 is the single diaphragm assembly.
1) Disconnect both vacuum sensing tubes from No. 1 vacuum
diaphragms. Pull choke lever link out fully and hold in place. Apply
more than 19.7 in. Hg to inner diaphragm. See Fig. 4.
2) Clearance should be .22-.24" (5.5-6.2 mm). Apply more
RX7Foragain.
iluvmyrx7.com
CARBURETOR
4-BBL
Article Text
2)1984 Mazda
than 19.7 in. Hg- NIKKI
to both
diaphragms
and(p.
measure
clearance
Clearance should be .45-.51" (11.5-13.0 mm).
Copyright © 1998 Mitchell Re
Fig. 4:
Choke Valve Opening Angle Adjustment
NO. 2 CHOKE DIAPHRAGM
1) Disconnect vacuum sensing tube from No. 2 vacuum
diaphragm. Pull choke lever link out fully and hold in place. Choke
valve should close fully. (Cool bi-metallic coil if necessary).
2) Apply more than 19.7 in. Hg to vacuum diaphragm and
measure clearance between choke valve and wall of air horn. Clearance
should be .057-.070" (1.46-1.80 mm).
CHOKE DIAPHRAGM OPERATION
(NO. 1 & NO. 2 DIAPHRAGMS)
Remove air cleaner. Start engine and run at idle. Disconnect
both vacuum sensing tubes from No. 1 diaphragm and one from the No. 2
diaphragm. Each diaphragm shaft should move outward from diaphragm.
CHECKING CHOKE DELAY
VALVE OPERATION
NOTE:
Automatic transmission must be in Neutral.
1) Warm engine to normal operating temperature. Stop engine
and remove air cleaner assembly. Disconnect inner vacuum sensing tube
from choke diaphragm No. 1.
2) Start the engine and run at idle speed. Diaphragm shaft
should move fully inward within 26-38 seconds after reconnecting
vacuum sensing tube to No. 1 choke diaphragm.
CHECKING AUTOMATIC
CHOKE RELEASE
1) With engine cold and ignition "OFF", pull choke knob out
fully and release. Knob should return automatically and freely.
Connect tachometer to engine.
2) Start engine and set engine speed at 2000 RPM with choke
knob. As engine temperature reaches range, choke knob should return
automatically and freely. See Fig. 5.
CARBURETOR - NIKKI 4-BBL
Article Text (p. 3)1984 Mazda RX7For iluvmyrx7.com
Copyright © 1998 Mitchell Re
Fig. 5:
Checking Automatic Choke Release
CHECKING CARBURETOR HEATER
1) Disconnect electrical connector from No. 1 water
temperature switch and connect jumper wire to both terminals of
connector. Connect tachometer to engine.
2) Disconnect carburetor heater electrical connector and
connect voltmeter to connector. Start engine and set engine speed at
2000 RPM with choke knob.
3) With choke knob pulled out, current should flow to
carburetor heater lead. Current should not flow to heater lead with
choke knob pushed in.
4) Connect ohmmeter between carburetor heater lead and
carburetor body. If ohmmeter shows no movement, carburetor heater is
defective and must be replaced.
CHECKING CHOKE MAGNET
Disconnect connector from choke switch. Using an ohmmeter,
connect leads to terminals 6 and 8 of connector. Continuity should
exist with choke knob in any position. With knob pulled out .4-.8"
(8-12 mm), continuity should exist between terminals 3 and 7. See
Fig. 6.
Fig. 6: Checking Choke Switch and Magnet
1984 Mazda RX7For iluvmyrx7.com
CARBURETOR
- NIKKI
4-BBL
Article
Text (p. 4)
Continuity should
be present
at terminals
6 and 8 with choke knob in
any position.
CHECKING CHOKE RELAY
Copyright © 1998 Mitchell Re
1) Disconnect connector from relay. Using an ohmmeter
without power applied, connect leads between terminals 1 and 2. There
should be continuity between terminals 1 and 2, but not between 3 and
4.
2) Connect battery power to terminal 6 and ground terminal
5. Continuity should now exist between terminals 3 and 4, but not at
terminals 1 and 2.
Fig. 7: Checking Choke Relay Continuity
Continuity should exist at terminals 1 and 2 without power applied;
at terminals 3 and 4 with power applied.
HOT START ASSIST CABLE
Pull hot start assist motor inner cable until stopper lever
touches start lever. Check for free play of .4-.8" (1-2 mm). See
Fig. 8. If free play is not within specified range, loosen screw,
adjust free play, and retighten screw.
Fig. 8:
Hot Start Assist Cable Adjustment
HOT START ASSIST RELAY
Disconnect connector from relay. Using an ohmmeter without
power applied, continuity should exist between terminals 1 and 4.
Connect battery power to terminal 2 and ground terminal 3. No
continuity should exist between terminals 1 and 4. See Fig. 9.
CARBURETOR - NIKKI 4-BBL
Article Text (p. 5)1984 Mazda RX7For iluvmy
Fig. 9: Checking Hot Assist Relay
There should be no continuity between terminals 1 and 4 with power
applied; continuity should exist without power.
THROTTLE OPENER
A/C Models Only
1) Turn off all accessories. Remove fuel filler cap.
Disconnect and plug idle compensator tube at air cleaner. Connect
tachometer to engine and warm engine to normal operating temperature.
2) Disconnect electrical connector from air switching
solenoid valve (Gray color). Disconnect and plug vacuum sensing tubes
from leading vacuum control units on distributor.
Fig. 10:
Throttle Opener Adjustment (A/C Models Only)
3) Turn off air conditioner switch. Disconnect electrical
connector from air conditioner solenoid. Connect battery power to one
terminal in connector and ground other terminal.
4) Throttle opener should operate and engine speed should
increase to 1150-1250 RPM in Neutral. If engine speed is not to
specification, turn adjusting screw. See Fig. 10.
CHECKING ALTITUDE COMPENSATOR
NOTE:
Altitude compensator must be checked at altitudes of
CARBURETOR
- NIKKI
Articlem).
Text (p. 6)1984 Mazda RX7For iluvmyrx7.com
1640-4920
ft. 4-BBL
(500-1500
1) Remove air cleaner and start engine. Engine should run
smoothly at specified idle. Place finger over slow port on carburetor
air horn; idle speed should drop.
Copyright © 1998 Mitchell Re
2) If idle speed did not drop, remove compensator valve and
blow through valve from both ports. Air should pass through
compensator valve. If not replace altitude compensator valve.
Fig. 11:
Adjusting Accelerator Cable and Pedal Height
ACCELERATOR CABLE ADJUSTMENT
1) Check accelerator pedal position. Pedal should be
1.5-1.9" (37-47 mm) lower than brake pedal. See Fig. 11. If
necessary, adjust nut "A" to obtain correct position.
2) Cable free play at carburetor should be .04-.12" (1-3
mm). To adjust free play, adjust nut "B". Depress accelerator to
floor and check that throttle valves are wide open. If necessary,
adjust stopper bolt.
OVERHAUL
NOTE:
Disassembly and assembly procedures will vary from vehicle
to vehicle due to emissions equipment and type of
transmission. Some carburetors may not have all parts
referred to in the following procedures.
DISASSEMBLY
1) Remove vacuum sensing tubes for altitude compensator
valve and choke delay valve. Remove choke heater lead, choke
diaphragm No. 2 vacuum sensing tube and altitude compensator valve.
2) Remove throttle opener and bracket assembly, No. 1 choke
diaphragm vacuum sensing tube, dashpot diaphragm and bracket assembly
(Man. Trans. only) and throttle return spring.
3) Remove sub-return spring, return spring bracket, bi-metal
spring housing and bracket assembly. Remove split pin and fast idle
rod, hot start assist lever spring and bracket assembly and choke
lever.
4) Remove the choke return diaphragm and bracket, No. 2
choke diaphragm and air horn assembly from main body. Disconnect
float pin and remove float, needle valve, spring, valve stem and
retainer.
CARBURETOR - NIKKI 4-BBL
Article Text
(p. 7)1984 Mazda RX7Fo
5) From main body, remove accelerator pump rod, secondary
throttle valve rod, throttle sensor and main body attaching bolts.
Remove main body from throttle body.
Fig. 12:
Removing Jets and Air Bleeds
6) Remove secondary throttle attaching screws, cover, return
spring, pin and clip, diaphragm, housing and gasket. Remove "E" clip,
washer and shaft, accelerator pump lever, attaching screws, cover,
diaphragm and return spring.
7) From main body, remove accelerator pump injection screw,
nozzle, gasket, weight, outlet check valve, check valve seat, weight
and inlet check valve. Remove retainer, blind plug and washer,
primary main jet and secondary main jet.
8) Remove air bleeds and jets. See Fig. 12. Using a hacksaw,
remove idle limiter cap by cutting through limiter cap, 0.4" (10 mm)
from cap end. Remove and discard mixture adjusting screw and spring.
CLEANING & INSPECTION
1) Wash all parts in clean solvent and clear all passages
using compressed air. Never use wire for cleaning jets, orifices or
passages. Inspect air horn, main body and throttle body for cracks or
breakage.
2) Inspect choke shaft and throttle shaft for wear, linkage
and connecting rods for bends, and return springs for damage. Inspect
float, needle valve and seat and strainer for damage.
3) To check air vent solenoid for proper operation, apply
battery voltage to solenoid valve, valve stem should pull into valve
body. Replace solenoid if it fails to operate properly.
REASSEMBLY
1) To reassemble, reverse the disassembly procedure, using
new gaskets. Avoid mixing primary and secondary system parts having
similar shape. When installing new mixture screw, seat lightly and
back out 3 turns for initial adjustment.
2) When installing bi-metal spring housing, fit choke shaft
lever to CARBURETOR
bi-metal spring - by
closing
choke valve
and8)
pulling
vacuum
1984
Mazda
RX7For iluvmyrx7.com
NIKKI
4-BBL
Article
Text (p.
Copyright © 19
CHOKE RETURN & HOT START ASSIST SYSTEM
Article Text
1984 Mazda RX7
For iluvmyrx7.com
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, June 08, 2002 10:45PM
ARTICLE BEGINNING
1984 Exhaust Emission Systems
MAZDA RX7 CHOKE RETURN & HOT
START ASSIST SYSTEMS
DESCRIPTION
The Choke Return system prevents the choke knob from being
left unreturned to prevent overheating of the exhaust system. The Hot
Start Assist system opens the throttle valve partially during
cranking of warm engine to optimize air/fuel mixture to improve
starting.
The choke return system components include No. 1 water
temperature switch, choke relay, choke magnet and choke switch. The
hot start assist system components include No. 1 water temperature
switch, hot start relay and hot start motor.
OPERATION
CHOKE RETURN SYSTEM
When cold engine is started with assist of choke knob, the
knob is held in pulled position by the choke magnet. Full release of
choke knob is achieved as engine coolant temperature reaches 158øF
(70øC). The No. 1 water temperature switch stops the flow of
electrical current to magnet and the choke knob is released.
HOT START ASSIST SYSTEM
During cranking of a warm engine, the No.
temperature switch provides power to the hot start
is engaged. When hot start relay is activated, the
pulls the hot start cable which opens the throttle
1 water
relay when starter
hot start motor
valve.
TESTING
CHOKE RETURN SYSTEM
1) With engine cold and ignition switch "OFF", pull choke
knob out fully. Choke knob should return automatically.
2) Connect tachometer to engine. Start engine and set engine
speed at 2000 RPM with choke knob. With engine running, choke knob
should automatically return when engine temperature indicator is in
position shown in Fig. 1.
Fig. 1:
Engine Temperature Indication for Release of Choke Knob
CHOKE MAGNET
Disconnect electrical connector from choke switch. Using an
ohmmeter, check continuity between terminals. Continuity should exist
between terminals number 6 and number 8. See Fig. 2.
Fig. 2:
Choke Switch Terminal Numbering
HOT START ASSIST SYSTEM
1) Inspect hot start assist cable and linkage for proper
installation, no binding or sticking, and full return. Warm engine to
normal operating temperature and stop engine.
2) Disconnect leading and trailing primary wires from
ignition coils. Crank engine. Hot start lever should open throttle
valve. If hot start system does not respond as outlined, check hot
start assist relay.
HOT START ASSIST RELAY
Disconnect electrical connector from hot start relay. Using
an ohmmeter, check continuity between the number 1 and number 4
terminals. Continuity should exist without power applied. Continuity
should not exist when power is applied to number 2 (positive) and
number 3 (negative) without power applied.
Fig. 3:
Hot Start Assist Relay Terminal Numbering
HOT START ASSIST CABLE ADJUSTMENT
Pull the start assist motor inner cable until the stopper
lever touches to the start lever and check free play. Free play
should be .04-.08" (1-2 mm). If not within specifications, loosen
cable and adjust.
Fig. 4:
Adjusting Hot Start Relay Cable
END OF ARTICLE
CHOKE RETURN & HOT START ASSIST SYSTEArticle Text (p. 21984 Mazda RX7For iluvmyrx7.com
DECELERATION CONTROL SYSTEM - CARBURETED
Article Text
1984 Mazda RX7
For iluvmyrx7.com
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, June 08, 2002 10:45PM
ARTICLE BEGINNING
1984 Exhaust Emission Systems
MAZDA RX7 CARBURETED MODELS
DECELERATION CONTROL SYSTEM
DESCRIPTION
The deceleration system is designed to maintain a balanced
air/fuel mixture during deceleration. System consists of 2
anti-afterburn valves, shutter solenoid valve, coasting/shutter
valve, throttle sensor, dashpot (manual transmission models) and
connecting hoses and wiring.
OPERATION
The number 2 anti-afterburn valve (located below air
cleaner) is actuated by the shutter solenoid valve to supply
additional air from air cleaner to intake manifold at initial
deceleration to prevent afterburning of fuel. The coasting/shutter
valve work together to supply air (coasting valve) and fuel (shutter
valve) during deceleration to prevent backfiring.
TESTING
NO. 1 ANTI-AFTERBURN VALVE
1) Warm up engine and run at idle speed. Disconnect the air
pump hose at the air pump. Place a finger over the air hose opening
and make sure that air is not sucked into the air hose at idling
speed.
2) Increase the engine speed more than 3000 RPM and then
decrease rapidly. Make sure the air is sucked into the air hose for a
few seconds while decelerating. Replace air control valve if it does
not operate properly.
NO. 2 ANTI-AFTERBURN VALVE
1) Warm engine and run at idling speed. Disconnect the air
hose running from air cleaner to number 2 anti-afterburn valve and
make sure that air is not sucked into the air hose at idling speed.
2) Increase the engine speed more than 3000 RPM and then
decrease the speed rapidly. Make sure the air is sucked into the air
hose for a few seconds while decelerating. Replace air control valve
if it does not operate properly.
Fig. 1:
Deceleration Control System
THROTTLE SENSOR
1) Warm engine to normal operating temperature. Stop engine
and connect tachometer. Disconnect Brown connector under air cleaner
on carbon canister side of engine.
2) Using 2 voltmeters, connect negative lead of each
voltmeter to each terminal in connector. Connect positive leads to
"B" terminal of alternator. See Fig. 2.
DECELERATION CONTROL SYSTEM - CARBURETED
Article Text (p. 2)1984 Mazda RX7For iluvmyrx7.co
Fig. 2:
Voltmeters Connected to Adjust Throttle Sensor
3) Start engine. Quickly decelerate engine from 3000 RPM and
make sure that current flows to both terminals when engine speed is
1000-1200 RPM. If current does not flow to both terminals at
specified speed, adjust throttle sensor.
4) To adjust sensor, remove cap from adjusting screw. Adjust
timing of current flowing to voltmeter A in Fig. 2 by turning
adjusting screw. Turning screw clockwise causes current to flow
earlier and turning screwing counterclockwise causes current to flow
later. See Fig. 3.
Fig. 3:
Throttle Sensor Adjusting Screw Location
4) After adjustment, install cap over throttle sensor
adjusting screw. Remove voltmeters and reconnect Brown connector.
Remove tachometer.
SHUTTER SOLENOID VALVE
1) Disconnect vacuum sensing tubes from shutter solenoid
valve (Yellow color dot). Blow through solenoid valve through vacuum
hose "B" shown in Fig. 4;. Make sure air passes through the valve and
comes out port "C".
2) Disconnect electrical connector and apply battery power
to terminals on solenoid valve. Blow through hose again. Air should
pass through valve and come out the air filter "A" of the valve.
Fig. 4:
Testing Shutter Solenoid Valve
SHUTTER SOLENOID VALVE SIGNAL CHECK
1) Warm engine to normal operating temperature and run at
idle speed. Connect a tachometer to engine. Disconnect the connector
from throttle sensor. Disconnect the air hose from the coasting valve
to air cleaner at the air cleaner.
2) Place a finger over the air hose opening and make sure
the air is not sucked into the air hose at idling speed. Increase the
engine speed more than 3000 RPM and then decrease rapidly. Make sure
the air is sucked into the air hose until the engine speed decreases
to 1000-1200 RPM.
3) On automatic transmissions, shift into "P" or "N".
Current should NOT flow to solenoid valve terminal at any engine
speed. If solenoid valve does not respond as described, replaceDECELERATION
shutter solenoid valve.
CONTROL S
DASHPOT (MAN. TRANS. ONLY)
1) Remove air cleaner. Check that dashpot rod does not bind
throttle lever movement. Quickly operate throttle lever fully and
make sure dashpot rod extends quickly.
2) Release throttle lever and make sure that throttle lever
returns slowly to idle position after it has touched dashpot rod.
Connect tachometer to engine. Start engine and warm to operating
temperature.
3) Ensure engine idle speed is adjusted to specification.
Operate throttle lever until it is away from dashpot rod. Slowly
decrease engine speed and check speed at which throttle lever just
touches dashpot rod. It should be 3800-4200 RPM. If not, loosen lock
nut and turn dashpot diaphragm to adjust engine speed.
END OF ARTICLE
DECELERATION CONTROL SYSTEM - CARBURETArticle Text (p. 4198
DECELERATION CONTROL SYSTEM - EFI
Article Text
1984 Mazda RX7
For iluvmyrx7.com
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, June 08, 2002 10:46PM
ARTICLE BEGINNING
1984 Exhaust Emission Systems
MAZDA RX7 FUEL INJECTED MODELS
DECELERATION CONTROL SYSTEM
DESCRIPTION
The deceleration system is designed to maintain a balanced
air/fuel mixture during deceleration. This helps prevent backfiring.
System consists of a fuel cut operation, throttle sensor, antiafterburn valve, and dashpot.
FUEL CUT SYSTEM TEST
During deceleration above a certain engine speed, fuel in not
injected from injectors. Fuel cut speeds are listed in the Fuel Cut
Speeds table. To check fuel cut operation, hold engine speed at 2000
RPM and make sure engine speed varies when throttle sensor is pushed
in with a finger.
Fuel Cut Speeds Chart
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Application
In Neutral ................
In Gear ...................
RPM
1500-1600
1200-1300
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
DECELERATION CONTROL SYSTEM - EFI
Article Text (p. 2)1984 Mazda RX7For iluvmyrx7.com
Fig. 1:
Deceleration Control System
THROTTLE SENSOR TEST
1) To check and adjust throttle sensor, proceed as follows.
Warm up engine then turn it off. Connect voltmeters to checking
connector (Green) as shown in Fig. 2.
2) Turn ignition switch on and check to see if current flows
to one of the voltmeters. If current flows to both voltmeters or does
not flow at all, turn throttle sensor adjusting screw until current
flows to one of the voltmeters.
3) If current flows to both voltmeters, turn adjusting screw
counterclockwise. If current does not flow at all, turn adjusting
screw clockwise. After adjusting, install cap onto adjusting screw.
Copyright
Fig. 2:
Voltmeters Connected to Adjust Throttle Sensor
4) Disconnect connector for throttle sensor. Connect an
ohmmeter to throttle sensor as shown in Fig. 3. Open throttle valve
and observe ohmmeter reading. At idle reading should be about 1000
ohms. Wide open reading should be about 5000 ohms.
Fig. 3:
Throttle Sensor Ohmmeter Connection
ANTI-AFTERBURN VALVE TEST
1) Warm up engine and run it at idling speed. Disconnect air
hose (air control valve-to-air pump) at air pump. Place a finger over
air hose opening and make sure that air is not sucked into air hose at
idling speed.
2) Increase engine speed more than 3000 RPM then decrease
engine speed rapidly. Make sure that air is sucked into air hose for a
few seconds while decelerating. Replace air cntrl valve, if necessary.
DASHPOT TEST
1) Check that dashpot rod does not keep throttle lever from
returning to idle stop. Quickly operate throttle lever fully and make
sure dashpot rod extends quickly.
2) Release throttle lever and make sure throttle lever
returns slowly to idle position after it has touched dashpot rod.
Connect tachometer to engine. Start engine and warm to operating
temperature. Make sure engine operates at specified idle speed.
3) Operate throttle lever until it is away from dashpot rod.
Slowly decrease engine speed and check speed at which throttle lever
just touches dashpot rod. It should be 2350-2650 RPM. If not, loosen
lock nut and turn dashpot diaphragm to adjust engine speed.
END OF ARTICLE
DECELERATION CONTROL SYSTEM - EFI
Article Text (p. 3)1984 Mazda RX7For iluvmyrx7.com
Copyright
EMISSION APPLICATION
Article Text
1984 Mazda RX7
For iluvmyrx7.com
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, June 08, 2002 10:46PM
ARTICLE BEGINNING
1984 ENGINE EMISSIONS
Mazda Emission Control Applications
626, GLC, Pickup, RX7
EMISSION CONTROL DEVICE APPLICATIONS
EMISSION CONTROL DEVICE APPLICATIONS TABLE
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
B2000 2.0L
PCV, AIS, EVAP, OC, EGR, AAV (1), ECC, DCS, HIC, ITCS,
PAS (2), TOCS
B2000 2.2L Diesel
PCV, EGR
GLC 1.5L
PCV, TAC, AIS, EVAP, OC, EGR, AAV (1), ASV, DCS, DP, ECC,
PAS, TOCS
RX7
TAC (3), EVAP, OC (3), O2, AAV, DCS, DP, ECC, EFE, EGI (4),
HIC (3), ITCS, MCS
626 2.0L
PCV, TAC, AIS, EVAP, OC, O2, AAV, DCS, EEC, ITCS, PAS, TOCS
(1)
(2)
(3)
(4)
-
A/T only.
Federal models only.
With 12A engines only.
With 13B engines only.
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
ABBREVIATION DEFINITIONS
ABBREVIATIONS DEFINITIONS TABLE
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Abbreviation
Description
AAV ...................................... Anti-Afterburn Valve
ACD .................................. Auxiliary Control Device
AI .............................................. Air Injection
AIS ...................................... Air Injection System
ASV ......................................... Air Suction Valve
CEC .............................. Computerized Engine Controls
CRV ..................................... Coasting Richer Valve
DCS ............................... Deceleration Control System
DP .................................................... Dashpot
ECC .......................... Electronic Controlled Carburetor
EEC ................................. Electronic Engine Control
EFE .................................... Early Fuel Evaporation
EGI ............................. Electronic Gasoline Injection
EGR ................................. Exhaust Gas Recirculation
EVAP ............................. Evaporative Emission Control
FCO .............................................. Fuel Cut-Off
HIC ...................................... Hot Idle Compensator
IC ......................................... Integrated Control
ITCS ........................... Ignition Timing Control System
MCS .................................... Mixture Control System
OC ........................................ Oxyidation Catalyst
O2 .............................................. Oxygen Sensor
PAS .......................................... Pulse Air System
PCV ............................ Positive Crankcase Ventilation
SPK ..................................................... Spark
TAC .................................. Thermostatic Air Cleaner
TOCS ............................. Throttle Opener Cont. System
TWC ........................................ Three-Way Catalyst
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
END OF ARTICLE
EMISSION APPLICATION
Art
FUEL EVAPORATION SYSTEM
Article Text
1984 Mazda RX7
For iluvmyrx7.com
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, June 08, 2002 10:46PM
ARTICLE BEGINNING
1984 Fuel Evaporation Systems
MAZDA ROTARY ENGINE
RX7
DESCRIPTION
System prevents escape of fuel vapors into atmosphere.
Components include a non-vented fuel tank with integral vapor
separator, check and cut valve (located at fuel tank), charcoal
canister, air vent solenoid valve (12A carbureted engine), purge
valve and connecting hoses.
OPERATION
When engine is not running, fuel vapors from fuel tank,
float bowl (12A carbureted engine), and engine are routed through
vent lines to charcoal canister where they are adsorbed. When engine
is running above idle, purge valve opens and fuel vapors are drawn
from canister and engine into intake manifold for burning. The purge
valve operates as the PCV valve and controls crankcase ventilation
and fuel evaporation.
CHECK & CUT VALVE
This valve has 3 functions: When fuel tank pressure becomes
too high, valve releases pressure to atmosphere. When vacuum becomes
too high, valve allows air into tank to prevent tank from collapsing.
If vehicle is overturned, valve prevents fuel leakage by sealing the
line with a check ball.
AIR VENT SOLENOID VALVE
When ignition key is off, air vent solenoid valve opens,
allowing fuel vapors in float bowl to travel to canister. When
ignition key is on, solenoid valve closes float bowl vent.
PURGE VALVE
A vacuum operated purge valve directs crankcase, fuel tank,
and canister vapors into intake manifold when the throttle is opened.
Fig. 1: Mazda RX7 Canister and Air Vent
Solenoid Location
TESTING
EVAPORATION LINE
From canister, remove evaporation hose leading to fuel tank.
Connect "U" tube pressure gauge to evaporation hose.
NOTE:
Evaporation line test is the same as on piston engines. To
complete testing procedure, see "TESTING, Evaporation Line"
in "Mazda Piston Engine" article in this section.
CHECK & CUT VALVE
NOTE:
Check and cut valve test is the same as on piston engines.
See "TESTING, Check and Cut Valve" in "Mazda Piston Engine"
article in this section.
Fig. 2:
Locating Check and Cut Valve on RX7
AIR VENT SOLENOID VALVE
Check solenoid air vent hose for cracks or damage.
Disconnect solenoid air vent hose from line. With ignition switch
off, slowly blow through hose. Air should pass through solenoid. Turn
ignition switch on, and blow through hose again. Air should not pass
through valve. If valve does not operate as described, replace valve.
PURGE VALVE
NOTE:
Purge valve test is outlined in Mazda article in "Crankcase
Ventilation" section. See "TESTING, Rotary Engines."
MAINTENANCE
Check system function every 15,000 miles. Check and Cut
Valve should be tested every 25,000 miles. Replace parts as necessary.
END OF ARTICLE
FUEL EVAPORATION SYSTEArticle Text (p. 21984 Mazda RX7For iluvmyrx7.com
FUEL INJECTION SYSTEM
Article Text
1984 Mazda RX7
For iluvmyrx7.com
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, June 08, 2002 10:47PM
ARTICLE BEGINNING
1984-85 Fuel Injection
MAZDA
RX7
DESCRIPTION
The electronically controlled fuel injection system precisely
meters the amount of fuel injected in each rotor. The Electronic
Control Unit (ECU) is the "brain" of the system.
The fuel delivery system consists of a fuel tank, filter,
pump, injectors, pressure regulator and pulsation damper. The air
delivery system consists of an airflow meter, air funnel, throttle
chamber, dynamic chamber and intake manifold.
OPERATION
The ECU uses input information to determine fuel output from
the following sensors and devices: airflow meter, throttle sensor,
intake air temperature sensor, atmospheric pressure sensor, engine RPM
(ignition pulse), coolant temperature, oxygen sensor and intake
manifold vacuum sensor.
After receiving the input information, the ECU will determine
the correct fuel pressure at the injectors by sending a signal to the
pressure regulator control solenoid valve. The ECU will also control
the fuel delivery volume by timing the duration of injector "ON" time.
Fig. 1:
Testing Fuel Pump Output Pressure
FUEL PUMP PRESSURE TEST
1) Disconnect negative battery terminal. Using a shop rag
wrapped around main fuel hose, disconnect main fuel hose from fuel
line. Connect a pressure gauge to line and reconnect negative battery
terminal.
2) Turn ignition on and jumper across 2 terminals of fuel
pump test circuit connector. See Fig. 1. Fuel pump pressure should be
50-71 psi (3.5-5.0 kg/cmý).
Fig. 2: Disconnecting Vacuum Hose from Fuel Pressure Regulator
Control Valve
PRESSURE REGULATOR FUEL PRESSURE
1) Disconnect negative battery terminal. Using a shop rag
wrapped around main fuel hose, disconnect main fuel hose from fuel
line. Using 3-way connector, connect pressure gauge to main fuel line.
2) Reconnect negative battery terminal. Start engine.
Disconnect vacuum hose between pressure regulator and pressure
regulator control valve at control valve. See Fig. 2.
3) With vacuum hose disconnected and engine idling, fuel
pressure should be approximately 37 psi (2.6 kg/cmý). Reconnect vacuum
hose to control valve and measure pressure. Fuel pressure should be
approximately 28.5 psi (2 kg/cmý). If not, replace fuel pressure
regulator.
FUEL INJECTION SYSTEM
Article Text (p. 2)1984 Mazda RX7For iluvmyrx7.com
Copyright © 1998 Mitchell Repa
FUEL INJECTION SYSTEM
Article Text (p. 3)1984 Mazda RX7For iluvmyrx7.com
Fig. 3:
Mazda RX7 Fuel Injection System Components
FUEL INJECTOR TESTS
Copyright © 1998 Mitchell Repa
INJECTOR OPERATION
1) Using a mechanic's stethoscope, listen to each injector
for normal "clicking" operating noise at idle and under acceleration.
2) If both injectors do not operate, ensure that there is
continuity in wire between trailing coil and terminal "U" of ECU
connector. If there is continuity, check main fusible link located
next to left strut tower.
3) If okay, turn ignition on and ensure that main relays (2)
click each time key is turned on. Main relays are located behind left
strut tower and are cylindrical in shape.
4) If main relays do not click when key is turned on, check
that battery voltage is present at main relay connector number 2
(Black/White wire). If not, repair open in circuit.
INJECTOR RESISTANCE
With electrical connector removed from injector, measure
resistance between injector terminals. Injector resistance must be in
range of 1.5-3.0 ohms. If not, replace injector.
INJECTOR FUEL LEAKAGE & DELIVERY VOLUME
1) Remove dynamic chamber and loosen delivery pipe attaching
bolts. Using wire, tie injectors tightly onto delivery pipe.
CAUTION: Ensure that injectors are tied tightly to fuel delivery
pipe. Failure to do so will cause fuel to spray out of loose
connections and cause fire hazard.
2) Turn ignition on and jumper between 2 terminals of fuel
pump test circuit connector. See Fig. 1. With system pressurized,
there should be no fuel leakage at injectors.
3) Leave system pressurized for 5 minutes and note any
leakage. Only a very slight amount of fuel leakage is acceptable.
4) Remove jumper from fuel pump test connector. Attach piece
of hose between injector and a graduated cylinder. Connect Injector
Checker (49 9200 040) to injector electrical connector. See Fig. 4.
CAUTION: Be extremely careful when connecting injector checker to
battery; always work away from sparks or open flames.
5) Turn ignition on, jumper fuel pump test connector and
energize injector by connecting injector checker's leads to battery
voltage. Measure injector fuel delivery volume for 15 seconds. Volume
produced in 15 seconds should be 5-6.7 oz. (.15-.2 L).
Fig.
Testing Injector
Delivery
FUEL4:
INJECTION
SYSTEM
Article
TextVolume
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Copyright © 1998 Mitchell Repa
PULSATION DAMPER TEST
Start engine and run at idle. Place finger over pulsation
damper and ensure damper pulsates. If not, replace pulsation damper.
ATMOSPHERIC PRESSURE SENSOR TEST
Turn ignition on. Using a voltmeter connected to the
atmospheric pressure sensor terminal "D", measure voltage. See Fig. 5.
Voltage should be 3.5-4.5 volts at sea level, or 2.5-3.5 volts above
an altitude of 6500 ft. (2000 m).
Fig. 5:
Testing Atmospheric Pressure Sensor
PRESSURE REGULATOR CONTROL VALVE TEST
1) Disconnect vacuum hoses from control valve. Blow into
valve port "B" and ensure that air passes out of valve through air
filter port "C". See Fig. 6.
2) Remove connector from control valve and energize control
valve by applying 12 volts to switch terminal. Ground other terminal.
Blow into valve port "B" and ensure that air passes out of valve
through port "C". If not, replace control valve.
Fig. 6:
Testing Pressure Regulator Control Valve
INTAKE AIR TEMPERATURE SENSOR TEST
Remove intake air temperature sensor from dynamic chamber.
Using a heat lamp, ohmmeter and thermometer, measure resistance of
sensor at various temperatures. See INTAKE AIR TEMPERATURE SENSOR
RESISTANCE specification table.
FUEL INJECTION SYSTEM
Article Text (p. 51984 Mazda RX7For iluvmyrx7.com
Copyright © 1998 Mitchell Repa
INTAKE AIR TEMPERATURE SENSOR RESISTANCE
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Temperature
Ohms
68øF (20øC) ................. 45,650-37,350
122øF (50øC) ................ 13,040-10,660
185øF (85øC) .................... 3850-3150
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
THROTTLE SENSOR TEST
For complete throttle sensor testing procedures, see the
ROTARY TUNE-UP article in the TUNE-UP section.
COOLANT TEMPERATURE SWITCH TEST
Coolant temperature switch is located in radiator. Using an
ohmmeter, check that switch closes in the 52-66øF (12-18øC)
temperature range.
COOLANT THERMO SENSOR TEST
Coolant thermo sensor is located in water pump. Using an
ohmmeter, check sensor resistance at various temperatures. See COOLANT
THERMO SENSOR RESISTANCE specification table.
COOLANT THERMO SENSOR RESISTANCE
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Temperature
Ohms
-4øF (-20øC) ................ 17,820-14,580
68øF (20øC) ..................... 2690-2210
176øF (80øC) ...................... 352-288
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
AIRFLOW METER TEST
Visually check airflow meter body for cracks or damage. Using
an ohmmeter, check resistance between airflow meter connector
terminals. See Fig. 7. See AIRFLOW METER RESISTANCE specification
table for resistance values.
AIRFLOW METER RESISTANCE
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Terminal
Ohms
E2 to VS ........................... 20-400
E2 to VC .......................... 100-300
E2 to VB .......................... 200-400
E2 to THA (1)
-4øF (-20øC) .............. 10,000-20,000
32øF (0øC) .................... 4000-7000
68øF (20øC) ................... 2000-3000
104øF (40øC) ................... 900-1300
140øF (60øC) .................... 400-700
E1 to FC .................... No Continuity
(1) - Intake air temperature sensor.
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
FUEL INJECTION SYSTEM
Article Text (p. 61984 Mazda RX7For iluvmyrx7.com
Copyright © 1998 Mitchell Repa
Fig. 7:
Checking Airflow Meter Resistance
AIRFLOW MEASURING PLATE TEST
Using a screwdriver, depress measuring plate fully and
measure resistance between terminals on airflow meter connector. See
AIRFLOW MEASURING PLATE RESISTANCE table for resistance values.
AIRFLOW MEASURING PLATE RESISTANCE
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Terminals
E1 to FC
Plate Fully
Plate Fully
E2 to VS
Plate Fully
Plate Fully
Ohms
Closed ........ No Continuity
Open ...................... 0
Closed ............... 20-400
Open ................ 20-1000
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
FUEL INJECTORS R & I
REMOVAL
1) Remove dynamic chamber assembly by removing air funnel,
accelerator cable, throttle sensor connector, metering oil pump
connecting rod and coolant hoses.
2) Disconnect negative battery cable, terminal cover, vacuum
hoses, air supply valve connector and intake air temperature sensor
connector.
3) Lift chamber assembly off of intake manifold and cover
intake manifold ports. Remove delivery pipe from top of injectors and
remove injectors.
INSTALLATION
Install new "O" rings on injectors and lubricate with
gasoline. To install injectors, reverse removal procedure. Check for
fuel leakage before installing dynamic chamber.
FUEL PUMP R & I
REMOVAL
FUEL INJECTION SYSTEM
Article Text (p. 71984 Mazda RX7For iluvmyrx7.com
Copyright © 1998 Mitchell Repa
1) Remove storage compartment located behind driver's seat.
Disconnect fuel pump connector and raise vehicle on hoist.
2) Remove pump bracket clamp bolt. Disconnect and plug inlet
and outlet hoses. Remove fuel pump from bracket.
INSTALLATION
To install, reverse removal procedure. Check for fuel
leakage.
IDLE SPEED ADJUSTMENT
For complete adjustment procedures, see the ROTARY TUNE-UP
article in the TUNE-UP section.
END OF ARTICLE
FUEL INJECTION SYSTEM
Article Text (p. 81984 Mazda RX7For iluvmyrx7.com
Copyright © 1998 Mitchell Repa
FUEL PUMP - ELECTRIC
Article Text
1984 Mazda RX7
For iluvmyrx7.com
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, June 08, 2002 10:48PM
ARTICLE BEGINNING
1984 Electric Fuel Pump
MAZDA
RX7, PICKUP
DESCRIPTION & OPERATION
Pulsating electric fuel pump is mounted near fuel tank on
frame member. Power is supplied when ignition switch is in "RUN"
position. This circuit is protected by a 15 amp fuse (20 amp on RX7)
at fuse panel. In-line fuel filter must be changed within recommended
mileage interval before performing tests. If in doubt, install new
filter.
TESTING
PRESSURE TEST
Fuel Pump (Carburetted Models)
1) Remove air cleaner assembly and disconnect fuel line at
carburetor. Connect pressure gauge with restrictor and a flexible
hose. See Fig. 1. Disconnect connector from fuel pump cut relay and
connect a jumper wire. See Fig. 2.
2) Turn ignition on and briefly vent the system into
container by opening hose restrictor. Pressure should stabilize at
2.8-3.6 psi (.19-.25 kg/cmý). If not within specifications, and lines
and filter are in satisfactory condition, replace pump.
Fig. 1:
Fuel Pump Pressure and Volume Test
Fig. 2:
Installing Jumper Wire
Fuel Pump (Fuel Injected Models)
1) Disconnect battery negative cable from battery. Disconnect
fuel main hose from fuel pipe. Connect a pressure gauge.
NOTE:
Cover the hose with waste cloth since fuel is splashed out
when disconnecting the hose.
2) Reconnect battery negative terminal. After turning
ignition switch to "ON" position, short-circuit fuel pump short
circuit terminal to start pump. See Fig. 3. Measure fuel pressure.
Outlet pressure should be 49.8-71.1 psi (3.5-5 kg/cmý).
Fig. 3:
Location of Short Circuit Terminal
Pressure Regulator (Fuel Injected Models)
1) Disconnect battery negative terminal. Disconnect fuel main
hose from fuel pipe. Connect pressure gauge between fuel main hose and
pipe by using 3-way joint.
NOTE:
Cover hose with waste cloth since fuel is splashed out when
disconnecting the hose.
2) Connect battery negative terminal, and start engine.
Disconnect vacuum hose connected to pressure regulator at pressure
regulator control valve. Measure fuel pressure at idle. Pressure
should be 36.97 psi (2.6 kg/cmý). Connect vacuum hose as it was, and
measure fuel pressure. Pressure should be 28.44 psi (2.0 kg/cmý).
VOLUME TEST
With fuel pressure within limits, open restrictor for one
minute and measure fuel expelled. If not within specifications, check
for restrictions in tank, line or filter. Replace pump if required.
FUEL PUMP VOLUME
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Application
Volume
Qt./Min. (cc/Min.)
RX7 (Carbureted Only) ................................... 1.5 (1400)
Pickup ................................................... 0.8 (800)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
REMOVAL & INSTALLATION
FUEL PUMP
Removal & Installation (B2000)
Disconnect negative battery cable. Unplug connector at fuel
pump. Disconnect inlet and outlet hoses at fuel pump. Remove fuel
pump-to-mounting bracket nuts and remove pump. To install, reverse
removal procedure.
FUEL PUMP - ELECTR
Removal & Installation (RX7)
Remove rear floor mat and disconnect fuel pump electrical
lead. Raise and support vehicle. Remove fuel pump cover. Disconnect
inlet and outlet hoses from pump. Remove fuel pump. To install,
reverse removal procedure.
PRESSURE REGULATOR
Removal & Installation
1) Remove intake manifold. Disconnect vacuum hose and fuel
return hose.
NOTE:
Cover starter motor with waste cloth to absorb any fuel
splashed on it.
2) Remove pressure regulator mounting nut and remove pressure
regulator. To install, reverse removal procedure and check for fuel
leaks.
END OF ARTICLE
FUEL PUMP - ELECTRIC
Article Text (p. 31984 Mazda RX7For iluvmyrx7.com
Copyrig
IGNITION CONTROL SYSTEM - CARBURETED
Article Text
1984 Mazda RX7
For iluvmyrx7.com
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, June 08, 2002 10:49PM
ARTICLE BEGINNING
1984 Exhaust Emission Systems
MAZDA RX7 CARBURETED MODELS
IGNITION CONTROL SYSTEM
DESCRIPTION
The Ignition Control system is used to regulate vacuum
advance of leading and trailing distributor systems. In addition,
this system helps reduce CO and HC emissions by aiding pellet
converter warm-up during cold engine starts.
System consists of leading and trailing components of the
distributor system, vacuum control solenoid valve and connecting
wiring and tubing.
OPERATION
The Ignition Control system operates when engine is cold and
running between 1000-1200 RPM and when engine is hot during quick
deceleration from 3000 RPM.
TESTING
NOTE:
For additional information and adjustments on distributor
spark timing, see appropriate information in "Mazda RX7
Systems & Tune-Up Service Procedures," article in this
section.
Fig. 1:
Ignition Control System
VACUUM CONTROL SOLENOID VALVE
SIGNAL CHECK
Leading Vacuum Control
Solenoid Valve Signal
1) Warm up engine to normal operating temperature. Connect a
tachometer to engine. Disconnect the vacuum sensing tube (from
leading vacuum advance diaphragm to pipe) at the pipe. Place a finger
over the pipe opening and make sure that air is not sucked into the
pipe.
2) Gradually increase the engine speed and make sure that
air is sucked into the pipe when the engine speed is 1000-2000 RPM or
more. Decrease the engine speed from 4000 RPM rapidly and make sure
air is not sucked into pipe while decelerating.
3) On vehicles with automatic transmissions, run the engine
at idling speed and make sure that air is sucked into the pipe when
the shift lever is in the "R", "D", "D1" or "D2" positions. On all
models, disconnect the connector from the number 1 water temperature
switch.
4) Connect a jumper wire to both terminals in the connector.
Pull out the choke knob about .6" (15 mm) and make sure that air is
not sucked into the pipe at any engine speed. Stop the engine and
disconnect the connector for the number 2 water temperature switch on
the radiator.
5) Pull the choke knob out about .6" (15 mm) and start the
engine. Increase the engine speed and make sure that air is sucked
into the pipe when the engine speed is 1000-2000 RPM or more.
Trailing Vacuum Control Solenoid
Valve Signal
1) Warm up engine to normal operating temperature. Connect a
tachometer to engine. Disconnect the vacuum sensing tube (from
trailing vacuum advance diaphragm to pipe) at the pipe. Place a
finger over the pipe opening and make sure that air is not sucked
into the pipe.
2) Gradually increase the engine speed and make sure that
air is sucked into the pipe when the engine speed is 2900-3100 RPM or
more. Decrease the engine speed from 4000 RPM rapidly and make sure
air is not sucked into pipe while decelerating.
3) On vehicles with automatic transmissions, run the engine
at idling speed and make sure that air is sucked into the pipe when
the shift lever is in the "R", "D", "D1" or "D2" position. On all
models, disconnect the connector from the number 1 water temperature
switch and connect a jumper wire to both terminals in the connector.
4) Pull out the choke knob about .6" (15 mm) and make sure
that air is not sucked into the pipe at any engine speed. Stop the
engine and disconnect the connector for the number 2 water
temperature switch on the radiator. Pull the choke knob out about .6"
(15 mm) and start the engine. Increase the engine speed and make sure
that air is sucked into the pipe when the engine speed is 1000-2000
RPM or more.
VACUUM SOLENOID VALVE
Leading Valve
1) Disconnect the vacuum solenoid sensing tubes from the
solenoid valve and vacuum pipe. Blow through the solenoid valve from
the vacuum sensing tube "B". Make sure the air passes through the
valve and comes out the air filter "C".
2) Disconnect the connector from the leading vacuum control
valve and connect battery power to terminals on the valve. Blow
through the valve from the vacuum sensing tube "B". Make sure the air
passes through the valve and comes out the port "A" of the valve.
IGNITION CONTROL SYSTEM - CARBURETED
Article Text (p. 2)1984 Mazda RX7For iluvmyrx7.com
Cop
Fig. 2:
Testing Leading Vacuum Control Solenoid Valve
Trailing Valve
1) Disconnect the vacuum solenoid sensing tubes from the
solenoid valve and vacuum pipe. Blow through the solenoid valve from
the vacuum sensing tube "B". Make sure the air passes through the
valve and comes out the air filter "C".
2) Disconnect the connector from the trailing vacuum control
valve and connect battery power to terminals on the valve. Blow
through the valve from the vacuum sensing tube "B". Make sure the air
passes through the valve and comes out the port "A" of the valve.
Fig. 3:
Testing Trailing Vacuum Control Solenoid Valve
IGNITION CONTROL SYSTEM - CARBURETED
Article Text (p. 3)1984 Mazda RX7For iluvmyrx7.com
END OF ARTICLE
Cop
IGNITION CONTROL SYSTEM - EFI
Article Text
1984 Mazda RX7
For iluvmyrx7.com
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, June 08, 2002 10:49PM
ARTICLE BEGINNING
1984 Exhaust Emission Systems
MAZDA RX7 FUEL INJECTED MODELS IGNITION CONTROL SYSTEM
DESCRIPTION
The Ignition Control system is used to regulate vacuum
advance of leading and trailing distributor systems. In addition,
this system helps reduce CO and HC emissions by aiding pellet
converter warm-up during cold engine starts.
System consists of leading and trailing components of the
distributor system, vacuum control solenoid valve and connecting
wiring and tubing.
OPERATION
The Ignition Control system operates when engine is cold and
running between 1000-1200 RPM and when engine is hot during quick
deceleration from 3000 RPM.
TESTING
Fig. 1:
Ignition Control System
VACUUM CONTROL SOLENOID VALVE
Checking for Signal
1) Warm up engine to normal operating temperature. Connect a
tachometer to engine. Disconnect the vacuum sensing tube (from
leading vacuum advance diaphragm to pipe) at pipe. Place a finger
over pipe opening and make sure air is not sucked into pipe. See
Fig. 2.
Fig. 2:
Checking for Signal
2) Gradually increase engine speed and make sure air is
sucked into pipe when engine speed is 1000-1200 RPM or more. Decrease
the engine speed from 4000 RPM rapidly and make sure air is not
sucked into pipe while decelerating. Turn A/C switch on and make sure
air is sucked into pipe at idling speed.
Testing for Faulty Valve
1) Disconnect vacuum sensing tubes from solenoid valve and
vacuum pipe. Blow through solenoid valve from port "B". Make sure air
passes through valve and comes out from air filter "C". See Fig. 3.
2) Disconnect connector from vacuum control solenoid valve
and connect battery power to terminals on valve. Blow through valve
from port "B". Make sure air passes through valve and comes out from
port "A" of valve.
IGNITION
CONTROL
SYSTEM
- EFI
Article Text
(p. 2)1984 Mazda RX7For iluvmyrx7.com
Fig. 3: Testing
Vacuum
Control
Solenoid
Valve
END OF ARTICLE
Copyright © 1998 Mi
IGNITION SYSTEM
Article Text
1984 Mazda RX7
For iluvmyrx7.com
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, June 08, 2002 10:50PM
ARTICLE BEGINNING
1984 Distributors & Ignition Systems
MITSUBISHI ELECTRONIC IGNITION - MAZDA ROTARY ENGINE
Mazda RX7
DESCRIPTION
The Mitsubishi electronic ignition system, used on the Mazda
RX7 rotary engine, is unique in that it has 2 sets of spark plugs
(leading and trailing). There is one set in the front rotor housing
and one in the rear rotor housing. See Fig. 1. There are also 2
ignition coils, 2 pick-up coils located in the distributor, and 2
coil-to-distributor high tension wires.
Fig. 1:
Schematic of RX7 Ignition System
There are 2 separate ignitors, mounted externally on the
distributor housing. One is for the leading side and the other for
the trailing side. Other system components include a battery,
ignition switch, ignition control switches, (water temperature,
altitude, etc.), and various relays.
All models are equipped with an ignition control system and
centrifugal advance mechanisms. All models have vacuum control units
for both leading and trailing sides.
OPERATION
A reluctor (signal rotor) is mounted on the reluctor (rotor)
shaft. It turns inside 2 magnetic pick-up coils, one for the leading
side and one for the trailing side. See Fig. 2.
As each tooth of the reluctor approaches and then passes the
leading pick-up coil, a signal is generated. It is sent to the
leading ignitor, which breaks the primary circuit in the leading
ignition coil.
As each tooth passes the leading pick-up coil, the previous
passing tooth approaches and becomes aligned with the trailing
pick-up coil. This triggers a signal to the trailing ignitor, which
breaks the primary circuit in the trailing ignition coil.
Therefore, immediately after the leading spark plug fires,
the trailing spark plug also fires, providing more complete and
efficient combustion while reducing HC and CO emissions.
As the primary circuit is broken in the leading and trailing
ignition coils, a voltage surge occurs in the secondary circuit of
the ignition coils. This high voltage is transmitted through the
leading and trailing high tension wires to the distributor, rotor and
spark plugs.
An emission control unit is also included in the ignition
control system, along with different sensing switches to provide
proper timing under varying engine operating conditions.
ADJUSTMENTS
RELUCTOR-TOPICK-UP COIL AIR GAP
1) Remove distributor cap and rotor. Turn distributor shaft
until the extended tooth of the reluctor (signal rotor) aligns with
core of pick-up coil. See Fig. 2.
2) Using a feeler gauge, check for .020-.035" (.5-.9 mm) air
gap. If gap is incorrect, replace pick-up coil and bearing assembly
or distributor drive shaft, as required.
Fig. 2: Adjusting Distributor Air Gap
Check air gap at all teeth and both pick-up coils.
IGNITION TIMING
1) To adjust leading timing, loosen distributor lock nut,
and rotate distributor housing until correct timing is obtained. See
Fig. 3.
2) To adjust trailing timing, loosen the screws securing the
trailing vacuum unit. Move the vacuum unit outward (to advance) or
inward (to retard). Retighten screws when correct timing is obtained.
IGNITION SYSTEM
Article Text
Fig. 3: Adjusting Ignition Timing
Distributor position determines leading timing. Vacuum unit position
adjusts trailing timing.
TESTING
HIGH TENSION WIRE
RESISTANCE CHECK
Turn ignition switch "OFF". Connect ohmmeter leads to each
end of coil-to-distributor high tension wire. Resistance should not
exceed 16,000 ohms (plus or minus 400 ohms) per 39.37" (1 m).
IGNITION COIL RESISTANCE CHECK
Set an ohmmeter in the low scale. With ignition switch
turned "OFF", and coil wires disconnected, attach ohmmeter leads to
primary terminals of leading coil and then trailing coil. Primary
resistance should be 1.22-1.48 ohms for each ignition coil.
PICK-UP COIL RESISTANCE CHECK
1) Set an ohmmeter in the x100 scale. Turn ignition switch
"OFF". Disconnect connector between ignitor and distributor. See
Fig. 4.
IGNITION SYSTEM
Article Text (p. 3)1984 Mazda RX7For iluvmyrx7.com
Copyright © 1998 Mitchell Repair Informatio
Fig. 4: Ohmmeter Hookup for Pick-Up Coil Resistance Check
Replace pick-up coil & bearing plate if reading is not 600-700 ohms.
2) Connect ohmmeter leads to leading terminals and then to
trailing terminals. Resistance should be 600-700 ohms at 68ø F (20ø
C) for each set of pick-up coils. If not, replace pick-up coil and
bearing assembly.
PICK-UP COIL OPERATION CHECK
1) With distributor connector still disconnected, touch
ammeter leads to leading terminals and then to trailing terminals.
2) Place a screwdriver against core of pick-up coil being
tested. Indicator of meter should move each time screwdriver is taken
quickly away from core. If not, replace pick-up coil and bearing
assembly.
IGNITOR CHECK
1) Remove ignitor from distributor base. Make a circuit as
shown in Fig. 5 using wire and a test bulb. Use a 12 volt bulb of
less than 10 watts.
Fig. 5: Test Lamp Hookup for Checking Ignitor Operation
Bulbs should flash when switch is operated.
2) Quickly operate switch "ON " and "OFF", and make sure
test lamp flashes. If not, replace ignitor.
OVERHAUL
DISASSEMBLY
1) Remove distributor cap, rotor and seal cover. See Fig. 6.
Remove ignitors and attaching screws from distributor housing. Remove
clips holding vacuum diaphragm links. Remove attaching screws and
vacuum control units from distributor housing. Remove condenser.
2) Remove reluctor shaft attaching screw from end of shaft.
Remove pick-up coil base bearing attaching screws. Remove reluctor,
reluctor shaft, pick-up coils and coil base bearing assembly from top
of distributor drive shaft.
3) Remove reluctor from reluctor shaft, using puller. Remove
spring pin. Remove governors by removing springs. Drive lock pin out
of drive gear, using a small drift. Remove gear and washers. RemoveIGNITION
SYSTEM
Article
drive shaft through top of distributor housing.
REASSEMBLY
1) Inspect distributor cap and rotor for cracks, carbon
tracks, and burned or corroded terminals.
2) Assemble distributor in reverse order of disassembly,
noting the following: Install reluctor shaft onto distributor drive
shaft, engaging slots of reluctor shaft and governor pins. Install
pick-up coil and coil base bearing assembly and tighten attaching
screws. Install reluctor on shaft, driving spring pin in with a punch.
Fig. 6:
Disassembled View of RX7 Mitsubishi Distributor
END OF ARTICLE
IGNITION SYSTEM
Article
MIXTURE CONTROL SYSTEM - CARBURETED MODELS
Article Text
1984 Mazda RX7
For iluvmyrx7.com
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, June 08, 2002 10:51PM
ARTICLE BEGINNING
1984 Exhaust Emission Systems
MAZDA RX7 CARBURETED MODELS
MIXTURE CONTROL SYSTEM
RX7
DESCRIPTION
Mixture control system controls air/fuel mixture ratio to
maintain optimum emission levels under a variety of operating
conditions. System consists of richer solenoid, various air bleeds,
altitude compensator and main air bleed control solenoid valve.
OPERATION
Signals from the electronic control unit (ECU) control the
richer solenoid and main air bleed control solenoid valve to control
fuel mixture.
Fig. 1:
Mixture Control System
TESTING
MAIN AIR BLEED CONTROL SOLENOID VALVE
1) Warm up engine and run at idling speed. Connect a
tachometer to the engine. Disconnect the connector from the throttle
sensor and connect a jumper wire to "A" and "C" terminals of the
connector.
2) Connect a voltmeter to the main air bleed control
solenoid (Brown) terminal and ground. Increase the engine speed and
observe the meter reading. At any engine speed between idle and 3000
RPM, voltage should be approximately 12 volts.
3) Between 3000-4000 RPM, voltage should be below 2 volts.
At more than 4000 RPM, voltage should be approximately 12 volts.
Disconnect the jumper wire connected to "A" and "C" terminals and
connect the connector to the throttle sensor.
4) Position the vehicle securely on a rolling road-tester.
Increase the vehicle speed and observe the voltmeter reading. At
speeds below 50 MPH, voltage should be approximately 12 volts. Above
50 MPH, voltage should be less than 2 volts.
Fig. 2:
Checking Signal for Main Air Bleed Control Solenoid Valve
RICHER SOLENOID VALVE SIGNAL
1) Start the engine and run at idle speed. Connect a
voltmeter to the richer solenoid valve terminal and ground, and take
reading. Voltage should be 12 volts. Increase the engine speed more
than 1500 RPM and then decrease it.
2) Voltmeter should show below 2 volts for 30 seconds when
the engine speed becomes 1100 RPM or less. Disconnect the vacuum
sensing tube of the vacuum switch at the idle compensator and take a
voltmeter reading. Voltage should be zero.
3) Reconnect the vacuum sensing tube to the idle
compensator. Disconnect the connector for the clutch switch. Depress
the clutch pedal and shift into first through fifth gears. Increase
the engine speed more than 1500 RPM and then decrease it. Voltmeter
should read 12 volts.
RICHER SOLENOID VALVE
Start the engine and run at idling speed. Ground the richer
solenoid terminal and make sure a clicking sound can be heard.
VACUUM SWITCH
Remove the vacuum switch. Connect a vacuum pump to the
vacuum switch. Connect an ohmmeter to the vacuum switch, and check
continuity between terminals. With 0-4.7 in. Hg vacuum applied,
switch should be open. With more than 4.7 in. Hg vacuum applied,
switch should be closed.
CLUTCH SWITCH
Disconnect clutch switch connector. Connect an ohmmeter to
the clutch switch, and check the continuity between the switch
terminals. There should be continuity when pedal is depressed, and
none when released.
NEUTRAL SWITCH
Disconnect neutral switch connector. Connect an ohmmeter to
the switch, and check the continuity between the switch terminals.
There should be continuity when transmission is in neutral range, and
none when in other ranges.
END OF ARTICLE
MIXTURE CONTROL SYSTEM - CARBURETED M
PCV SYSTEM
Article Text
1984 Mazda RX7
For iluvmyrx7.com
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, June 08, 2002 10:52PM
ARTICLE BEGINNING
1984 Crankcase Ventilation
MAZDA
B2000, B2200, GLC, RX7 & 626
DESCRIPTION & OPERATION
PISTON ENGINE MODELS
Gasoline
The PCV system includes 2 hoses and a PCV valve. Crankcase
vapors are normally drawn from valve cover through PCV valve and into
intake manifold. A hose from the air cleaner to the valve cover
supplies fresh air to the crankcase.
When intake manifold vacuum drops due to heavy loads,
the amount of blow-by exceeds the capacity of the PCV valve. Air then
flows directly from the valve cover into the air cleaner and
carburetor. When engine is not running, the PCV valve is closed and
vapors are stored in the crankcase.
Diesel
The crankcase ventilation system on diesel engines consists
of a breather hose connecting an upper chamber in valve cover with
air intake. Oil baffle plates are located in upper chamber of valve
cover. Blow-by gases are fed into the air intake and prevented from
entering the atmosphere. Servicing is limited to keeping breather
hose and passages free of obstructions.
Fig. 1: 626 Crankcase Ventilation System
Note direction of flow.
ROTARY ENGINE MODELS
The crankcase ventilation system on the rotary engine (RX7)
is an integral part of the fuel evaporation system. A vacuum operated
purge valve directs crankcase, fuel tank, and canister vapors into
intake manifold when the throttle is opened.
Fig. 2:
B2200 Diesel Pickup Crankcase Ventilation System
TESTING
PISTON ENGINE MODELS
GLC
Remove PCV valve. Blow through valve with mouth pressure
from valve cover side of valve. Air should pass through. Blow through
valve from opposite end. Air should not pass through. If valve does
not operate as described, replace valve.
626
With engine idling at normal operating temperature, remove
PCV valve from valve cover. Close off valve opening with finger and
check that idle speed drops. If idle speed does not drop, replace
valve. See Fig. 3.
Fig.
3: Testing
626Text
PCV (p.
Valve
PCV SYSTEM
Article
2)1984 Mazda RX7For iluvmyrx7.com
PCV valve is connected to ventilation hose.
Copyright © 1998 Mitchell Repair Information Com
B2000
With engine at normal operating temperature and key off,
remove hose from PCV valve. Run engine at idle and place finger over
the PCV valve inlet. If idle speed does not drop, replace PCV valve.
NOTE:
To replace PCV valve on California models with automatic
transmissions and on all Federal models, first remove
carburetor. Carburetor removal is not necessary on other
B2000 models.
ROTARY ENGINE MODELS
1) Disconnect purge valve-to-oil filler tube hose from purge
valve. Start engine and run at idle speed. Place finger over open
purge valve port and feel that no vacuum is present. See Fig. 4.
2) Increase engine speed to 2000 RPM and feel that vacuum is
present at purge valve port. If valve does not operate as outlined,
replace purge valve.
Fig. 4: RX7 Rotary Engine Purge Valve
Check air flow at port leading to oil filler tube.
MAINTENANCE
Check PCV system operation every 30,000 miles or 30 months.
END OF ARTICLE
PCV SYSTEMArticle Tex
VACUUM DIAGRAMS
Article Text
1984 Mazda RX7
For iluvmyrx7.com
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, June 08, 2002 10:52PM
ARTICLE BEGINNING
1984 Exhaust Emission Systems
MAZDA RX7 VACUUM DIAGRAMS
Fig. 1:
Vacuum Diagram For Carbureted RX7 Models
For iluvmyrx7.com
VACUUM
DIAGRAMS
Article
2)1984 Mazda
Fig.
2: Vacuum
Diagram
ForText
Fuel(p.
Injected
RX7 RX7
Models
END OF ARTICLE
Copyright © 1998 Mitchell Repair Inform
TUNE-UP - ROTARY
Article Text
1984 Mazda RX7
For iluvmyrx7.com
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, June 08, 2002 10:52PM
ARTICLE BEGINNING
1984 Mazda Rotary Tune-Up
TUNE-UP
RX7
IDENTIFICATION
ENGINE IDENTIFICATION
The RX7 will have one of two engines, a carbureted model and
a EGI (Electronic Gasoline Injection) model, regulated by a computer.
The engine code for both models is stamped on the rear rotor housing,
to the rear of the oil filter. The engine serial number is stamped on
the front rotor housing behind the distributor.
ENGINE CODE
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Application
Code
1.1L Carbureted ................................................
1.3L Fuel Injected .............................................
12A
13B
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
TESTING
ENGINE COMPRESSION
The manufacturer recommends using a special compression
tester (49 0820 280K or 49 H075 280). Compression testers for piston
engines will read only the highest pressure of the 3 combustion
chambers in the rotor housing.
Warm engine to operating temperature. On 12A engine, remove
both trailing spark plugs. On 13B engine remove trailing spark plug on
chamber being tested only.
COMPRESSION SPECIFICATIONS TABLE
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Application
Specification
Min. Compression Pressure ............ 85 psi (6.0 kg/cmý)
Max. Variation ....................... 21 psi (1.5 kg/cmý)
Compression Ratio .................................. 9.4:1
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
SPARK PLUGS
SPARK PLUG TYPE
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Nippondenso No.
NGK No.
W25EDR14
BR8EQ14
...................................................
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
SPARK PLUG SPECIFICATIONS TABLE
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Gap: In. (mm)
0.055 (1.4)
Torque: Ft. Lbs. (N.m)
................................................
11 (15)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
HIGH TENSION WIRE RESISTANCE
Carefully remove high tension wires from spark plugs and
distributor cap. Using an ohmmeter, measure resistance of wires while
gently twisting wires. If resistance is not to specifications, or
fluctuates from infinity to any value, replace high tension wire(s).
HIGH TENSION WIRE RESISTANCE
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Application
All Models
Ohms
...........................................
4880 per Foot
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
ADJUSTMENTS
DISTRIBUTOR
All models are equipped with Mitsubishi electronic ignition
with 2 pickup coils. Air gap is nonadjustable.
Fig. 1:
Firing Order and Distributor Rotation
IGNITION TIMING
NOTE:
On vehicles equipped with automatic transmission, block the
wheels and place selector lever in "D" position.
1) Warm engine to normal operating temperature. Connect a
tachometer, then connect timing light to leading (lower) spark plug of
front rotor. Start engine and run at idle speed.
2) Aim timing light at timing indicator pin on front cover
and check ignition timing. Rotate distributor to correct timing, if
necessary. Tighten distributor lock nut and recheck timing.
3) Connect timing light to trailing (upper) plug of front
rotor. Start engine and check timing. If not correct, loosen vacuum
unit attaching screws. Move vacuum unit in or out to adjust trailing
timing. Remove test equipment.
TUNE-UP - ROTARY
Art
Fig. 2: Connecting Timing Light
Check leading plug timing first.
Fig. 3:
Ignition Timing Mark Location
IGNITION TIMING (ATDC @ 800 RPM)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Application
Timing
Leading
Carbureted Models ............................................. 0ø
Fuel Injected Models .......................................... 5ø
Trailing
Carbureted Models ............................................ 20ø
Fuel Injected Models ......................................... 20ø
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
IDLE SPEED
Carbureted Models
1) Switch off all accessories. Remove fuel filler cap.
Disconnect and plug idle compensator tube at air cleaner. Connect
tachometer to engine. Ensure parking brake is engaged and wheels are
TUNE-UP
Article Text (p. 3)1984 Mazda RX7For iluvmyrx7.com Copyright © 1998 Mitchell Repair Informa
blocked. - ROTARY
2) On manual transmission models, make sure dashpot rod does
not keep throttle lever from returning to stop. On air conditioned
models, make sure throttle opener does not keep throttle lever from
returning to stop.
3) Warm engine to normal operating temperature. Place
automatic transmission in "D". Check idle speed. Adjust curb idle
speed to specification by turning throttle adjusting screw.
Fuel Injected Models
1) Turn off all accessories. Connect a tachometer to engine.
Ensure parking brake is engaged and wheels are blocked. Remove fuel
filler cap. Warm up engine until it reaches normal operating
temperature.
2) Check and adjust throttle sensor before adjusting idle
speed. Disconnect vent and vacuum solenoid harness connector located
near oil filler hole. See Fig. 4.
Fig. 4: Vent and Vacuum Solenoid Harness Connector
Disconnect harness before adjusting idle speed on EFI Models.
3) Place transmission in Neutral and check idle speed. Adjust
idle speed by removing plug and turning air adjusting screw. See
Fig. 5. After adjustment, reinstall plug and reconnect vent and vacuum
solenoid harness connector. Install fuel filler cap and remove
tachometer.
Fig. 5: Adjusting Idle Speed on Fuel Injected Models
Remove plug and turn air adjusting screw to obtain idle speed.
IDLE SPEED
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Application
RPM
Carbureted Models .......................................... (1) 750
Fuel Injected Models ........................................... 800
(1) - Man. Trans. in Neutral & Auto. Trans. in "D".
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
TUNE-UP - ROTARY
Article
Text (p
IDLE MIXTURE
NOTE:
Mixture adjustment is not part of normal tune-up procedure
and should not be performed unless carburetor is overhauled
or vehicle fails emissions testing.
Carbureted Models
1) Idle mixture adjustment requires removal of carburetor to
remove limiter cap. Using a hacksaw, cut through limiter cap and
mixture screw 0.4" (10 mm) from cap end. Remove mixture screw and
install new mixture screw.
2) To install new mixture screw, tighten screw lightly and
ensure it is fully seated. Back screw out 3 turns for preliminary
adjustment. Reinstall carburetor with new gaskets and warm engine to
normal operating temperature.
3) To adjust idle mixture, set idle speed to idle set
specification by turning throttle set screw (automatic transmission in
"N"). Set idle speed to highest RPM obtainable by turning mixture
screw. Reset idle speed to idle set specification by turning throttle
screw. See Fig. 6.
4) Turn mixture screw until lean drop specification is
obtained (automatic transmission in "N"). On automatic transmission,
shift transmission to "D" and set idle speed to curb idle
specification by turning throttle screw.
MIXTURE ADJUSTMENT (CARBURETED MODELS ONLY)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Application
Idle Set RPM
Man. Trans. ..................
Auto. Trans. (1) .............
770
870
Lean Drop RPM
...........................
...........................
750
840
(1) - Transmission in Neutral.
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Fig. 6:
Carburetor Adjusting Screw Locations
Fuel Injected Models
1) With ignition off, disconnect harness connector at
variable resistor on airflow meter and connect ohmmeter leads to
variable resistor. If resistance is not 500-4500 ohms between
terminals A-C and B-C, replace resistor and adjust mixture.
2) Switch off all accessories. Remove fuel filler cap and
connect tachometer to engine. Warm engine to operating temperature.
Check and adjust throttle sensor as required. Disconnect vent and
vacuum solenoid valve harness connector. See Fig. 4.
3) Adjust idle speed by turning air adjusting screw. Turn
TUNE-UP - ROTARY
Art
variable resistor to obtain highest idle speed. Turn air adjusting
screw to set idle speed. Turn variable resistor counterclockwise until
idle speed is 780 RPM and then turn resistor clockwise until idle
speed is 800 RPM.
4) Connect vent and vacuum solenoid harness. Install plug
over air adjusting screw. Fill space above variable resistor screw
with adhesive (N304 23 795). Remove tachometer and install fuel filler
cap.
THROTTLE SENSOR
Carbureted Models
1) Warm engine to normal operating temperature. Stop engine
and connect tachometer. Disconnect Brown connector under air cleaner
on carbon canister side of engine.
2) Using 2 voltmeters or 12-volt, 3-watt bulbs, connect
negative lead of each voltmeter to each terminal in connector. Connect
positive leads to "B" terminal of alternator. See Fig. 7.
Fig. 7: Voltmeters Connected to Adjust Throttle Sensor
This applies only to carbureted models.
3) Start engine. Quickly decelerate engine from 3000 RPM and
make sure that current flows to both voltmeters or bulbs at the same
time. If current does not flow at the same time, adjust throttle
sensor.
4) To adjust sensor, remove cap from adjusting screw. Adjust
timing of current flowing to voltmeter "A" in Fig. 7 by turning
adjusting screw. Turning screw clockwise causes current to flow
earlier and turning screw counterclockwise causes current to flow
later. See Fig. 8.
Fig. 8: Throttle Sensor Adjusting Screw Location
This applies to carbureted models.
5) After adjustment, install cap over throttle sensor
adjusting screw. Remove voltmeters and reconnect Brown connector. TUNE-UP
- ROTARY
Article
Remove tachometer.
Fuel Injected Models
1) Warm engine to operating temperature. Stop engine and
disconnect Green connector. Using 2 voltmeters, connect leads to Green
connector terminals. See Fig. 9. Turn ignition on and observe
voltmeters. Current should flow to 1 of the voltmeters.
Fig. 9: Voltmeters Connected to Adjust Throttle Sensor
This applies to fuel injected models.
2) If current flows to both voltmeters, remove throttle
sensor adjusting screw cap and turn adjusting screw counterclockwise.
If current does not flow to either voltmeter, turn adjusting screw
clockwise. See Fig. 10. Remove test equipment. Reconnect Green
connector and insert cap over throttle adjusting screw.
Fig. 10: Adjusting Throttle Sensor
Turn adjusting screw to adjust current flow to voltmeters.
COLD (FAST) IDLE RPM
TUNE-UP - ROTARY
Article T
NOTE:
Carburetor must be removed to check and/or adjust fast idle.
Carbureted Models Only
Adjust fast idle by setting angle of primary throttle valve
with choke valve fully closed. Clearance between primary throttle
valve and throttle bore should be .040-.047" (1.0-1.2 mm). If not to
specification, bend fast idle rod until correct clearance is obtained.
SERVICING
EMISSION CONTROL
See EMISSIONS section.
SPECIFICATIONS
IGNITION
Distributor
All models are equipped with Mitsubishi electronic ignition
with 2 pickup coils. Air gap is nonadjustable.
IGNITION COIL RESISTANCE - OHMS @ 68øF (20øC)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Application
All Models
Primary
...................
.9
Secondary
............................
N/A
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
FUEL SYSTEM
FUEL PUMP PERFORMANCE
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Application
Pressure: psi (kg/cmý)
Volume in 30 Sec.: Pints (L)
Carbureted ....... 2.8-3.6 (.2-.3) .....................
Fuel Injected .. 49.8-71.1 (3.5-5.0) ...................
3.0 (1.4)
3.6 (1.7)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Carburetor
Carbureted models use a Nikki 4-Bbl. carburetor.
Fuel Injection
Fuel injected models employ the EGI (Electronic Gasoline
Injection) system.
BATTERY
BATTERY SPECIFICATIONS TABLE
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Application
Standard
Optional
Amp Hr. Capacity
........................................................
........................................................
50
55
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
STARTER
All models are equipped with a Mitsubishi starter using an
overrunning
clutch.Article Text (p. 8)
1984 Mazda RX7For iluvmyrx7.com Copyright © 1998 Mitchell Repair Informa
TUNE-UP - ROTARY
STARTER SPECIFICATIONS TABLE
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Application
Volts
Man. Trans. ..........
Auto. Trans. .........
11.5
11.5
Amps
...........
...........
Test RPM
60 ................
100 ...............
6500
3500
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
ALTERNATOR
All models are equipped with a Mitsubishi alternator.
ALTERNATOR SPECIFICATIONS TABLE
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Application
All Models
Rated Amp Output
......................................................
50
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
ALTERNATOR REGULATOR
All models are equipped with a Mitsubishi voltage regulator.
REGULATOR OPERATING VOLTAGE @ 68øF (20øC)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Application
All Models
Voltage
....................................................
13.5
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
BELT ADJUSTMENT
BELT ADJUSTMENT
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Application
(1) Deflection In. (mm)
Alternator Belt ...................................... .5-.7
Air Pump Belt ...................................... .43-.51
A/C Belt ........................................... .39-.47
Pwr. Stg. Belt ..................................... .39-.47
(13-17)
(11-13)
(10-12)
(10-12)
(1) - Deflection is with 22 lbs. (10 kg) pressure applied midway
on longest belt run.
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
INTERVALS
REPLACEMENT INTERVALS
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Component
Interval (Miles)
Engine Oil .................................................... 7500
Oil Filter .............................................. (1) 15,000
Air Filter .................................................. 30,000
Spark Plugs ................................................. 30,000
(1) - Every 7500 miles under severe conditions.
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
CAPACITIES
TUNE-UP - ROTARY
Article Text (p. 9)1984 Mazda RX7For iluvmyrx7.com
Copyright ©
FLUID CAPACITIES
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Application
Quantity
Crankcase (Includes Filter)
Carbureted Models ................................ 4.9 qts. (4.6L)
Fuel Injected Models ............................. 5.8 qts. (5.6L)
Cooling System (Includes Heater) .................. 10.0 qts. (9.5L)
Man. Trans. (SAE 90) ............................... 1.8 qts. (1.7L)
Auto Trans. (ATF Type F) ........................... 7.9 qts. (7.5L)
Rear Axle (SAE 90)
Standard ......................................... 2.6 pts. (1.2L)
Limited Slip ..................................... 3.4 pts. (1.6L)
Fuel Tank ......................................... 16.4 gals. (63L)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
END OF ARTICLE
TUNE-UP - ROTARY
Article Text (p. 101984 Mazda RX7For iluvmyrx7.com
Copyright © 1998 Mitchell Repair Inform
1.2L ENG NO POWER/STUMBLE/ROUGH IDLE/BUCKING CAT. 4, NO. 014/85
Article Text
1984 Mazda RX7
For iluvmyrx7.com
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, June 08, 2002 10:54PM
ARTICLE BEGINNING
TECHNICAL SERVICE BULLETIN
APPLICATION
1981-85 RX7 (High Altitude Vehicles)
SUBJECT
No Power, Stumble, Rough Idle, Bucking, Etc.
REFERENCE
Mazda Motors Corp., Service Bulletin, No. 4 014/85, August, 1985
CONDITION & CAUSE
Some 1981-85 RX7 high altitude vehicles may exhibit one or more of the
following driveability problems:
*
*
*
*
Lack of acceleration, hesitation on acceleration
No power under load
Engine stumble, surge or bucking below approximately 3000 RPM
Rough idle
One or more of the above conditions may be caused by the altitude
compensator valve. The altitude compensator valve is attached to the
carburetor to supply additional air into the carburetor at high
altitudes (1640-4920 ft.)
REPAIR
1) Remove the altitude compensator valve. Blow through the valve from
port "A" and "B". Above 4920 feet, air from port "A" should exit from
port "D" and air into port "B" exits from port "C".
2) Below 1640 feet air should not pass through valve. If not, replace
the altitude compensator valve (N249 20 770).
END OF ARTICLE
1.2L HARD CRANK/NO START - CARBON IN ROTOR/HOUSING CAT. 1, NO. 103/83
Article Text
1984 Mazda RX7
For iluvmyrx7.com
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, June 08, 2002 10:55PM
ARTICLE BEGINNING
TECHNICAL SERVICE BULLETIN
HARD CRANKING
Models
Bulletin No.
Category
Date
Symptom
RX7
103/83
1
5/7/83
Hard Cranking/No Start
DESCRIPTION
If RX-7 vehicles have not been in use for a long period of time and
the engine is cranked with a weak battery, hard cranking may occur due
to carbon trap.
When the vehicles have been stored for such a long period of time
carbon accumulated on the rotor surface may be flaked off, and it can
be trapped between the rotor and rotor housing by the sweeping motion
of the apex seals only when the engine is started. It will not occur
when the engine is running.
To verify carbon trap, the following two conditions must be
confirmed:
l) The problem occurred when the engine was started.
2) The apex seal can be observed through one of the leading spark
plug holes. (If carbon trap occurs, the rotor will always stop
at this location).
If carbon trap is verified, please use the following procedure:
Procedure:
I. For vehicles with manual transmission:
1) Disconnect the negative battery cable and remove the spark
plugs.
2) Hoist the vehicle, remove the starter and install the Flywheel Turning Tool, P/N 49FA 42 065. This special tool is
newly established for vehicles with manual transmission.
3) Turn the Flywheel Turning Tool counterclockwise (as shown
in Fig. 1 until the force is reduced considerably).
CAUTION: Do not turn the Flywheel in the direction of normal engine
rotation.
Fig. 1:
View of Flywheel Turning tool (49FA 42 065)
4) Remove the special tool (Fig. 2) and reinstall the starter.
Fig. 2:
Using Flywheel Turning Tool
5) Lower the vehicle. Turn the front pulley clockwise, facing
the rear of the car, with a l9mm wrench. At the same time,
inject 20-30 cc of engine oil through carburetor. Do not
exceed the specified quantity of oil.
6) Turn the engine approximately five (5) revolutions to make
certain the engine rotates freely.
NOTE: Do not use the starter to rotate the engine.
7) Install the spark plugs.
8) Check that the battery is fully charged.
9) Start the engine and warm up to normal operating
temperature.
10) Stop the engine. Remove the spark plugs and check
compression. If the compression is over 6.0 kg/cmý, the
repair is completed.
II. For vehicles with automatic transmission:
1) Disconnect the negative battery cable and remove the spark
plugs.
2) Remove the inspection plate from the converter housing.
(Fig. 3).
Fig. 3:
Removing Inspection Plate From Convertor Housing
3) Insert a standard screwdriver through the inspection hole.
Turn the flywheel by prying against the flywheel teeth and
converter housing as shown until the force is reduced
considerably.
CAUTION: Do not turn the flywheel in the direction of normal engine
1.2L HARD
CRANK/NO START - CARBON IN ROTOR/HOUSING CAT. 1,
rotation.
4) Follow the procedure in I, steps 5-10.
END OF ARTICLE
NO. 103/83
Article Text (p. 2
1.3L ENG NO START/BLOWN FUSE - SHORT IN WIRE HARNESS CAT. 15, NO. 012/85
Article Text
1984 Mazda RX7
For iluvmyrx7.com
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, June 08, 2002 10:55PM
ARTICLE BEGINNING
TECHNICAL SERVICE BULLETIN
APPLICATION
1979-84 RX7
SUBJECT
"ENGINE" Fuse Blows/No Start
REFERENCE
Mazda Motors Corp., Service Bulletin, No. 15 012/85, September, 1985
CONDITION & CAUSE
Some 1979-84 RX7 vehicles may exhibit an "ENGINE" fuse that blows,
preventing the engine from starting. This problem may be caused by an
electrical short circuit in the wiring harness.
REPAIR
Check for a short circuit in the wire harness in the area of the
thermostat and air hose to the air cleaner. See Fig. 1.
Fig. 1:
View of Wiring Harness
END OF ARTICLE
1.3L ENG SECONDARY AIR CONTROL SYSTEM MODIFICATION CAT. 4, NO. 002/84
Article Text
1984 Mazda RX7
For iluvmyrx7.com
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, June 08, 2002 10:56PM
ARTICLE BEGINNING
TECHNICAL SERVICE BULLETIN
SECONDARY AIR CONTROL SYSTEM MODIFICATION
Model: 1984 RX-7 (12A)
Bulletin No.: 002/84
Date: 7/13/84
Category: 4
DESCRIPTION
The Secondary Air Control System has been modified since the
production date of March 1984.
Now air is injected behind the No. 1 pre-month converter when the Port
Air Switching Valve (newly added to the Air Control Valve) is open.
Port and split air operation remain the same as previous years.
Fig. 1:
Secondary Air Control System Modification
OPERATION
The Port Air Switching Valve will open between 3,000-4,000 rpm or
above 50 mph.
VIN OF PRODUCTION CHANGE
RX-7 (12A):
JMIFB331 E0824687 March, 1984
Fig. 2:
Parts Information Table
1.3L ENG SECONDARY AIR CONTROL SYSTEM MODIFICATION CAT. 4, NO. 002/84
Article Text (p.
Fig. 3:
Air Control Valve Assembly
CHECKING PROCEDURE
PORT AIR SWITCHING VALVE
Checking Port Air Switching Valve:
1. Warm up the engine and run it at idling speed.
2.
Connect a tachometer to the engine.
3. Disconnect the connector from the throttle sensor and connect a
jumper wire to A and C terminals of the connector.
Fig. 4:
Jumper Wire Installation
4. Connect a voltmeter to the port air switching valve (R) terminal
and ground.
5.
Increase the engine speed and observe the voltmeter reading.
Engine Speed (rpm)
Idling speed - 3.000
3,000-4,000
more than 4.000
Voltage (V)
approx. 12
below 2
approx. 12
6. Disconnect the jumper wire connected in step 3 and connect the
connector to the throttle sensor.
Fig. 5:
Voltmeter Connections
7. Position the vehicle on a rolling-road tester. See Fig. 6
WARNING:
Use wire rope 1.3L
to secure
the vehicle soAIR
it CONTROL
doesn't move
ENG SECONDARY
SYSTEM
MODIFICATION CAT
forward.
Fig. 6:
Positioning Vehicle on Road Tester
8. Increase the vehicle speed and observe the voltmeter reading.
Below 50 MPH - approx. 12V
Above 50 MPH - below 2V
Due to the addition of the Port Air Switching Valve in the Air Control
Valve the wiring harness has been changed as shown in Fig. 7.
1.3L ENG SECONDARY AIR
Fig. 7:
Wiring Harness Modifications
1.3L ENG SECONDARY AIR CONTROL SYSTEM MODIFICATION CAT. 4, NO. 002/84
Article Text (p.
Fig. 8:
View of Fuse Panel
1.3L ENG STALL/POOR IDLE - THROTTLE SENSOR ADJ CAT. 4, NO. 009/84
Article Text
1984 Mazda RX7
For iluvmyrx7.com
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, June 08, 2002 10:56PM
ARTICLE BEGINNING
TECHNICAL SERVICE BULLETIN
IDLE SPEED ADJUSTMENT
Model: 1984-1985 RX-7 (13B)
Bulletin No.: 009/84
Date: 10/26/84
Symptom: Stall, Poor Idle
Category: 4
DESCRIPTION
Improper adjustment of the idle speed may cause poor idle stability or
engine stall when coming to a stop. Either of these problems are
encountered, please follow the Checking Procedure described.
CHECKING PROCEDURE
1. Warm up the engine to the normal operating temperature. Confirm
that the fast idle cam separates from the roller as shown. If the
fast idle cam is contacting the roller, the engine is not fully
warmed. (Fig. 1)
2. Stop the engine and turn the key to the "ON" position.
Fig. 1:
View of Fast Idle Cam
3. Connect the voltmeter to the throttle sensor checking connector
(Green) and check the voltage as shown. (Fig. 2)
(a) Terminal (A) - approximately 12v & Terminal(B) - 0v:
Throttle sensor adjustment is OK, Go to Step 4.
Fig. 2:
Checking Throttle Sensor Voltage
(b) Terminal (A) - approximately 12v & Terminal(B) - approximately
12v: Throttle sensor out of adjustment. Adjust as follows:
Turn the adjust screw counter-clockwise until the voltage at
terminal(B) becomes 0. Then turn the adjust screw an additional 1/4 to
1/2 turn counter-clockwise. Confirm that the voltages at terminals (A)
and (B) are as shown in Step 3(a).
Fig. 3:
Adjusting Throttle Sensor
(c) Terminal (A) - Ov &
Terminal (B) - Ov:
Throttle sensor out of adjustment. Adjust as follows:
Turn the adjust screw clockwise until the voltage at terminal (A)
becomes approximately 12v. Then turn the adjust screw an additional
1/4 to 1/2 turn clockwise. Confirm that the voltages at terminals (A)
and (B) are as shown in Step 3(a). (Fig. 3)
4. Start the engine and run it at idle.
5. Disconnect the connector for the vent and vacuum solenoid valves.
Turn all accessories off. (Fig. 4)
1.3L ENG STALL/POOR IDLE - THROTTLE SENSOR ADJ CAT. 4, NO. 009/84
Article Text (p. 2)1984 M
Fig. 4:
Disconnecting Solenoid Valves Connector
Check the idle speed. Adjust the idle speed to specification, if
necessary, by turning the air adjust screw. (Fig. 5)
Idle speed: 800 rpm
Fig. 5:
Adjusting Idle Speed
Use a jumper wire to ground the LW wire for the air supply valve as
shown. Confirm that the engine speed increases to 1000-1070 rpm. (
Fig. 6)
NOTE:
Step 7 must be done with the connector for vent and vacuum
solenoid valves disconnected
Fig. 6:
View of Air Supply Valve
Adjust the engine speed to specification, if necessary, by turning the
1.3L
ENG STALL/POOR
THROTTLE
SENSOR
ADJ CAT. 4, NO. 009/84
Article
air-supply
valve adjust IDLE
screw- as
shown. (Fig.
7)
Text (p. 3)1984 M
Fig. 7:
Adjusting Engine Speed
Reconnect the vent and vacuum solenoid valve connectors disconnected
in Step 5.
END OF ARTICLE
1.3L ENG STALL/POOR IDLE - THROTTLE SENSOR ADJ CAT. 4, NO. 009/84
Article Text (p. 4)1984 M
BAD SHUTTER VALVE CAUSES ROUGH IDLE/NO IDLE
Article Text
1984 Mazda RX7
For iluvmyrx7.com
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, June 08, 2002 11:00PM
ARTICLE BEGINNING
TECHNICAL INFORMATION TIP
ROTARY ROUGH IDLE
YEAR(S):
MANUFACTURER:
MODELS:
DATE OF ISSUE:
ISSUE:
1982-85
Mazda
RX-7
June 1993
BAD SHUTTER VALVE CAUSES ROUGH IDLE/NO IDLE
A bad shutter valve may cause a rough or no idle on 1982-85
Mazda RX-7 models. To test the shutter valve, remove the hose from the
valve (it's located below the carburetor) and check for vacuum. If
there is vacuum at idle, the shutter valve is bad and should be
replaced.
Another thing to check that may be causing your idle problems is
the vacuum hose that leads from the carburetor to the AA valve. This
large hose may be burned or split at the bend in the hose near the
intake manifold and can introduce a large vacuum leak if it's leaking.
Courtesy of Import Service Magazine
with thanks to:
Bill Jasper
Charles Levy Motor Company
Columbus, Georgia
REFERENCE NUMBER:
NOTE:
MAZ0518AP
This information has been obtained from sources generally
believed to be reliable. Use your own judgment before relying
on this data. Neither the suppliers of these Technical
Information Tips, nor Mitchell International, guarantees or
assumes responsibility for data accuracy or completeness, nor
is liability assumed by the suppliers of these Technical
Information Tips or Mitchell International for any claims or
damages resulting from the use of this information.
END OF ARTICLE
HI IDLE SPRRD OR HUNTING IDLE - NEW THROTTLE BODY CAT. 4, NO. 008/84
Article Text
1984 Mazda RX7
For iluvmyrx7.com
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, June 08, 2002 10:57PM
ARTICLE BEGINNING
TECHNICAL SERVICE BULLETIN
HIGH IDLE SPEED OR IDLE SPEED HUNTING
Model:
Category:
Bulletin No.:
Date:
1984 RX-7 (13B)
4
008/84
10/15/84
DESCRIPTION
If you encounter either of the following problems on 1984 RX-7 (13B)
vehicles with the engine fully warmed, please follow the repair
procedure described.
1. Engine speed hunts between approximately 1500-2000 rpm at idle.
2. Engine speed stays approximately 1200-1500 rpm at idle.
REPAIR PROCEDURE
1. Throttle Body.
Rotate the secondary throttle valve lever counter-clockwise by hand as
shown while the idle speed is high or hunting.
If this procedure corrects the problem, the high idle is due to
sticking of the secondary throttle valve, shown in Fig. 1. Replace the
throttle chamber (N304 20 S00B) in this case.
If this procedure does not correct the problem, go to Step 2.
Fig. 1:
View of Secondary Throttle Valve Lever
2. Vent Solenoid Valve.
Disconnect the vacuum hose (Fig. 2) from the vent solenoid valve and
plug the inlet port of the vent solenoid valve with a finger as shown
in Fig. 3 while the idle speed is high or hunting.
Fig. 2:
Disconnecting Vent Solenoid Valve Vacuum Hose
If this procedure corrects the problem, the high idle is due to a
faulty vent solenoid valve. Replace the vacuum switch valve (N304 13
240), which includes the vent solenoid valve, in this case.
Fig. 3:
Plugging Vent Solenoid Valve Inlet Port
END OF ARTICLE
HI IDLE SPRRD OR HUN
TAS (THROTTLE ADJUSTMENT SCREW) LOCATION/ADJUSTMENT CAT. F, NO. 014/98
Article Text
1988 Mazda RX7
For iluvmyrx7.com
Copyright © 1998 Mitchell Repair Information Company, LLC
Tuesday, June 11, 2002 09:33AM
ARTICLE BEGINNING
TECHNICAL SERVICE BULLETIN
TAS (THROTTLE ADJUSTMENT SCREW) ADJUSTMENT
Model(s):
Category:
Bulletin No.:
Date:
All Mazda Models with Fuel Injection
F (01) - Fuel & Emission Control
014/98
December 9, 1998
VEHICLES AFFECTED
All fuel injected models.
DESCRIPTION
Fuel injected vehicles with idle speed control motors should NOT
have the TAS (Throttle Adjustment Screw) adjusted for any reason. The
TAS functions as a stopper when the throttle valve is fully closed.
During production, the TAS is accurately set by measuring the airflow
rate past a closed throttle plate. Any adjustment to this screw will
affect PCM control of idle speed.
Customers complaining of low idle speed should have their vehicle
repaired using the Workshop Manual.
NOTE:
* Tampering with this screw will affect the idle contact switch
and/or throttle position sensor settings. This can lead to
rough idle and difficulty in diagnosis of idle quality
concerns.
* The TAS locations on the examples below may vary depending on
model year of vehicle. See Fig. 1.
Fig. 1:
Throttle Adjustment Screw Locations
END OF ARTICLE
WHISTLE NOISE FROM CHECK &CUT VALVES - REPL VALVES CAT. 4, NO. 015/85
Article Text
1984 Mazda RX7
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Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, June 08, 2002 10:59PM
ARTICLE BEGINNING
TECHNICAL SERVICE BULLETIN
APPLICATION
1980-85 RX7 & 1981-85 GLC
SUBJECT
Whistle Noise From Check & Cut Valve
REFERENCE
Mazda Motors Corp., Service Bulletin, No. 4 015/85, September, 1985
CONDITION & CAUSE
Some 1980-85 RX7 and 1981-85 GLC vehicles may exhibit a whistle noise
from the check and cut valve. The whistle noise is most noticeable at
high temperature and low fuel level, and can be heard from the rear of
the vehicle.
REPAIR
Replace the check and cut valve with the new service component (RX7 8341-42-910, GLC - BA01-42-910).
Fig. 1:
Anything Installation
END OF ARTICLE